ANSYS Workbench Research Articles

Evaluation of Heat Dissipation Efficiency in Rectangular Heat Sinks with Ceramic Coating across Different Base Materials

The design of the heating system is critical in achieving optimal thermal efficiency. Solid Works, a well-known design software, was used to meticulously create heat sink fins in both rectangular and square designs. The company’s choice strikes a good balance between practical manufacture and outstanding heat dissipation. When the design was complete, a modification process was performed to boost their efficiency. The heat fins were coated with a thin layer of SiO2 thermal coating that was precisely 0.25 mm thick. Heat is effectively transferred away from the electronic components because to the remarkable thermal properties of this silicon dioxide layer. Aluminum alloy (Al-alloy) and copper alloy (Cu-alloy). The thermal characteristics of the two materials vary. It is anticipated that performance would change upon merging with the SiO2 layer, defining the conditions for a comparative analysis. ANSYS Workbench ® was used to analyze and objectively assess the performance of many heat sink designs that differed. The whole temperature distribution and heat flow of the settings two critical factors that determine the effectiveness heat management in thermal systems would be shown by this sophisticated instrument.

Wall panel structure design optimization of a hexagonal satellite

Considering that it satisfies high strength and stiffness at a low weight, the grid structure is the ideal option for meeting the requirements for developing the wall panel structure for the satellite. The most attractive grid structures for the satellite wall panel industry are isogrid and honeycomb structures. The first part of this work involves studying the mechanical and dynamic performance of five designs for the satellite wall panel made of 7075-T0 Al-alloy. These designs include two isogrid structures with different rib widths, two honeycomb structures with different cell wall thicknesses, and a solid structure for comparison. The performance of these designs was evaluated through compression, bending, and vibration testing using both finite element analysis (FEA) with the Ansys workbench and experimental testing. The FEA results are consistent with the experimental ones. The results show that the isogrid structure with a lower rib thickness of 2 mm is the best candidate for manufacturing the satellite wall panel, as this design reveals the best mechanical and dynamic performance. The second part of this work involves studying the influence of the length of the sides of the best isogrid structure in the range of 12 mm–24 mm on its mechanical and dynamic performance to achieve the lowest possible mass while maintaining the structure’s integrity. Then, a modified design of skinned wall panels was introduced and dynamically tested using FEA. Finally, a CAD model of a hexagonal satellite prototype using the best-attained design of the wall panel, i.e., the isogrid structure with a 2 mm rib width and 24 mm-long sides, was built and dynamically tested to ensure its safe design against vibration. Then, the satellite prototype was manufactured, assembled, and successfully assessed.

Analiza elastično-plastičnog naprezanja skupljajućih debelih FGM cilindara

This paper addresses the stress analysis of shrink-fitted thick-walled cylinders made of functionally graded material (FGM). Analytical solutions are provided for the elastic-plastic behavior of shrink-fitted axisymmetric thick-walled FGM cylinders based on the linear plane elasticity theory and plasticity laws. Due to the material's functional gradation, mechanical characteristics like Young's modulus, yield stress, and plastic parameters are controlled by a power function along the wall thickness. Considering a plane strain case, elastic-perfectly plastic model and Von Mises yield criterion; theoretical solutions are obtained for both elastic and plastic phases. The radial, hoop, axial, and equivalent Von Mises stresses are obtained for up to 25%, 50%, and 75% of cylinder plasticization for the elastic and plastic zones. Stresses are given in terms of interference and geometrical and mechanical parameters of the assembly. In addition, the interferences to start plastic deformation and the full plastic collapse of the cylinder are discussed. Moreover, the effect of the gradient index on the contact pressure and both the start of yield and plastic collapse pressures are conducted. The analytical results found in the current research are compared with the numerical solutions carried out by Ansys Workbench. Both results show a good agreement.

CALCULATING THE NATURAL FREQUENCY OF PRE-TWISTED BEAM

Beams in two configurations; uniform and non-uniform, are common structural components utilized for several engineering applications. Thus, the studies dealing with their behavior under dynamic and vibrations have been increased. In this research, the transverse vibration phenomena of pre-twisted beams were experimentally and theoretically studied by investigating the effect of twisting angles on the first three transverse natural frequencies. In the present experimental part, the pre-twisted beams are manufactured using a 3D printer, and the fundamental frequencies of manufactured pre-twisted beams are measured by a suitable rig. In the theoretical work, the finite element method is used to simulate the transverse vibration behavior of the pre-twisted beams. The accuracy of the simulation process is checked by comparison of the first natural frequencies calculated by the finite element method (using ANSYS Workbench Software) with those measured experimentally. The results show that there is an excellent agreement between the experimental results and finite element outputs. For the clamped-free pre-twisted beam, there is no critical twisting angle. The critical twisting angle is equal to the mode number for simply – simply and clamped simple pre-twisted beam. While there is more than one value of critical twisting angle for the clamped-clamped pre-twisted beam.

Design, analysis and optimization of porous titanium alloys scaffolds by using additive manufacture

In order to have a stronger bond with the surrounding bone, the bone prosthesis needs to have interconnecting pores for bone cells to grow and more importantly to avoid stress shielding. At the same time, human bones have different composition and structure of bone tissue in different parts of the body due to different physical factors of the person, so the elastic modulus of the bones that need to be supported and replaced are not the same. And additive manufacturing has the advantages of rapid, efficient and precise manufacturing of complex shapes and high-quality three-dimensional structures, which can manufacture porous scaffold bone prosthesis, and achieve more accurate mechanical property requirements by controlling the design parameters. To study the effect of design strut length and design strut cross-section diameter size on the elastic modulus of tetrahedral titanium alloy scaffold unit, and with the help of UG NX, several digital models of porous titanium alloy scaffolds were constructed with the strut length and the strut cross-section diameter size as the parameters of variation, and then the elastic modulus of each porous titanium alloy scaffold was measured by ANSYS Workbench 2022, and the elasticity modulus of each porous titanium alloy scaffold was further derived from the relationship between the strut length and strut cross-section diameter size and the porous titanium alloy scaffold. Then the elastic modulus of each porous titanium alloy bracket was measured by ANSYS Workbench 2022, and the mathematical model between the strut length, strut cross-section size and elastic modulus of the porous titanium alloy bracket was further derived. Then, ANSYS Workbench 2022 was used to measure the elastic modulus of each porous titanium alloy bracket and further derive the mathematical model between strut length, strut cross-section diameter size and elastic modulus of the porous titanium alloy bracket, with the help of which the elastic modulus of the porous titanium alloy bracket with specific diameters and strut lengths was finally deduced to validate the correctness of the above predicted mathematical model, and to make reasonable explanations and corrections for the deviations. explanation and correction of deviations. As a result, the rapid prototyping technology can be used to design the required porous titanium alloy bracket in a more detailed way.

FEA simulation of harmonics generation from 6-pulse rectifier and their impact over rectifier’s transformer

In the present work, the operation of a 6-pulse three-phase rectifier supplying a powerful DC consumer is simulated using the finite element method (FEM). The purpose of the simulations is to research the generation of harmonics from the rectifier circuit and to investigate their influence on the transformer supplying the three-phase bridge rectifier. For this purpose, two co-simulations were made. The first of them is realized with the help of the professional Finite Element Analysis (FEA) software - Ansys Electromagnetic Suite. The voltage-driven model of the rectifier transformer for FEA was built and was used in the Ansys Twin Builder software simulation. The resulting current harmonics from the FFT analysis of the current waves with their amplitudes and phases are input into the primary and secondary windings of the transformer current-driven model in the second electromagnetic-thermal co-simulation in Ansys Workbench to calculate the losses in the transformer. These losses are used in the thermal model to account for transformer heating from higher harmonics.

A simulation study on mechanical properties and heat conductivity of magnesium matrix syntactic foams before and after heat treatment

Environmental pollution and energy consumption problems today are seriously affecting people’s lives. In this paper, a new magnesium AZ31B matrix syntactic foam (MMSF) prepared by gravity penetration with hollow alumina microspheres as reinforcement was simulated using ANSYS Workbench for the lightweight design of vehicles. The mechanical properties and heat conductivity of MMSFs prepared by hollow microspheres with different diameters and volume fractions before and after heat treatment were investigated using finite element analysis. The simulation results showed that the MMSF prepared by hollow microspheres with a diameter of 3.6 mm and a volume fraction of 40% had the best mechanical properties and heat conductivity after heat treatment strengthening. Due to low density, high strength, excellent thermal insulation and other advantages, this high-performance MMSF is suitable for making vehicle bodies, which can effectively reduce the overall weight, thus reducing the fuel consumption and pollutant emission caused by driving.

Research on Crack Limit Dimension of Pressure Vessel Based on FAD Diagram

Pressure vessels are widely used in petrochemical, aerospace, transportation and other industries. In the process of processing, it will form surface opening defects, and these defects will threaten the production safety. In order to effectively avoid the occurrence of safety accidents and understand the service life of pressure vessels, it is necessary to predict and analyze the crack limit size. In response to the problem of complex stress and difficulty in theoretical calculation after cracks appear on the surface of pressure vessels, this article uses the ANSYS Workbench platform to simulate and analyze the pressure vessels and obtain relevant parameters such as stress intensity factor and stress. Through calculation, the toughness ratio and load ratio are obtained. Using the FAD Failure Assessment Diagram, the ultimate crack size of pressure vessels under safety conditions is obtained. This method provides a reference for crack analysis methods and safe use of pressure vessels.

ТЕОРЕТИЧЕСКОЕ ОБОСНОВАНИЕ РАБОТЫ ТЕРМОЭЛЕКТРИЧЕСКОГО ГЕНЕРАТОРА В СРЕДСТВАХ ТЕПЛОВОЙ ПОДГОТОВКИ АВТОТРАКТОРНОЙ ТЕХНИКИ

This article describes a new approach to improving the energy efficiency of thermal preparation devices for automotive equipment using a thermoelectric generator, which reduces the energy consumption of thermal preparation devices and preserves the capacity of the battery before starting the engine in the cold season. A mathematical model of heat transfer and removal from a thermoelectric generator, developed and numerically implemented in the Solidworks and Ansys Workbench software environments, is described, taking into account the design features of the proposed heat exchange devices. Analytical dependences are presented for calculating the generated electric energy by a thermoelectric generator in different operating modes with heat exchange devices of different structures.

Axial compressive behavior of recycled aggregate concrete steel composite columns

In this Study the axial load-carrying capacity and behavior of a “Axial Compressive behavior of Recycled Aggregate Concrete Steel Composite Columns” (RACSCC) is investigated experimentally and simulated numerically. The study emphasizes the utilization of materials contributing to the circular economy in construction, specifically integrating steel and recycled aggregate into concrete. The environmentally sustainable concrete columns are formed by filling square steel tube sections with recycled aggregate concrete (RAC). The study includes six SRACC specimens and one bare conventional steel column. The specimens are subjected to axial compressive loading using the displacement control method. The investigation explores the impact of different coarse aggregate sizes of 12 mm, 16 mm, 22.4 mm, 25 mm, and 30 mm, obtained through sieving of demolished buildings materials. The study aims to address the impact of varying aggregate sizes on parameters such as maximum load-carrying capacity, strain, stress, lateral displacement, and failure patterns. The experimental results are validated and compared with the maximum load-carrying capacity, Strain, Stress, Lateral displacement, and failure patterns using numerical simulations conducted with the Ansys Workbench tool. The SRACC column comprises a hollow tube with 20 mm to 22.4 mm and 22.4 mm to 25 mm recycled aggregate and has a maximum load carrying capacity of 610.28 kN at 10 mm displacement. The local buckling failure occurred near the area load applied. The numerical simulations result for the composite columns agreed well with the experimental results. The results show the recycled aggregate concrete (RAC) have a massive potential for construction support in circular economy. To create composite columns using the RAC as an alternative building material that will help to create an environmentally Sustainable construction

Numerical analysis of inflow turbulence intensity impact on the stress and fatigue life of vertical axis hydrokinetic turbine

The present study aims to analyze the effect of upstream turbulence intensity on the hydrodynamic and structural performance of the straight-blade vertical axis turbine. To achieve this, a one-way fluid structure interaction analysis is conducted within the ANSYS workbench environment. Initially, computational fluid dynamics (CFD) simulation is performed at different values of upstream velocity values. Additionally, the impact of upstream turbulence intensity is also analyzed. The CFD simulation results were validated against published experimental work. Once CFD simulation is performed then computed fluid loads are transferred to the ANSYS mechanical structural module. Finite element modeling is performed to compute the stresses and the fatigue life. The study reveals that increasing the upstream turbulence intensity from 5% to 20% leads to 8.6% improvement in the turbine's power performance. However, turbulence intensity also results in 35.6% increase in Von-Mises stresses produced within the designed turbine. However, even with this increase, the Von-Mises stresses remain below a critical threshold, measuring at 173.34 MPa when the upstream water velocity is 1.4 m/s, and the inflow turbulence intensity is at 20%. This stress level is well within the material's yield strength, ensuring the turbine's structural integrity. Moreover, the simulation results emphasize that turbulence intensity has a significant impact on the turbine's fatigue life. Further, it is predicted that an increase in turbulence intensity from 5% to 20% leads to a significant 40% reduction in the turbine's fatigue life. The stress analysis results reveal that struts, strut–blade joints, and strut–shaft joints are the key stress concentration areas. The results suggested that an increase in upstream turbulence intensity has favorable impact on turbine performance, however, for highly turbulent flows turbine should have higher strength and key areas should be focused on designing turbine for such flow conditions.

Оценка прочности каркаса кабины машиниста грузового локомотива при аварийных столкновениях

The article is based on an analysis of consequences after emergency collisions of freight locomotives at railway crossings. It assesses the strength of the driver’s cabin frame the design of which uses standard rolled and bent-welded profiles made of low-alloy steel. During the research calculations were performed using the finite element (FE) method in two software systems - foreign system ANSYS WORKBENCH 2023R1 and domestic system LIRA 10.12. Two FE models were developed using beam and shell finite elements which made it possible to evaluate the strength of the stress-strain state of the driver cabin frame. Based on the calculation results conclusions were drawn about the applicability of each of the models and possible directions for further research in the field of modeling emergency collisions of freight locomotives were proposed.

Computational Fluid Dynamics Analysis of 3D Wind Flow around Rhizophora Mangrove Tree and Drag Force Acting on the Wall of the Tree

Many natural disasters, such as cyclones, typhoons, mudslides, and tsunamis, are currently plaguing the world. These tragedies, which have destroyed the coastal settlements, claim a great number of lives each year. The characteristics and structure of the Mangrove tree have the significant impact on protecting the coast from heavy wind, floods, mudslides, and other kinds of natural disasters. This research work investigates how Mangroves can protect the area near the coast from a fluid dynamics point of view. Complex real world problems require intelligent systems that combine knowledge and techniques. Hence Computational Fluid Dynamics (CFD) technique namely the finite volume method is employed as a tool in this study. In this research, a model Rhizophora Mangrove tree from Pichavaram Mangrove forest, Tamilnadu, India is generated using Ansys Workbench design modeler. A computational domain is created around this tree to reduce the boundary effect. Grid-independent research was carried out using various mesh sizes to determine the best grid resolution for the analysis. An unstructured triangular mesh was generated for the simulation. The focus of this study is to determine the 3D flow around the tree in order to determine the wind velocity, as well as the coefficient of drag and drag force on the wall tree. This research helps to give a clear understanding of wind flow around the 3D Rhizophora Mangrove tree. The velocity profile, pressure distribution, drag force, and drag coefficient around the tree are captured, analysed, and presented in detail. The results show that the Rhizophora mangrove trees can significantly reduce the flow velocity of the wind and will be able to safeguard the coast and communities nearby from natural disasters.

Simulation of Multi-Layered Ballistic-Resistant Armour with Enhanced Energy Absorption Properties

This research focuses on the simulation of ballistic impact on multi-layered ballistic resistant armour. The efficiency of spring-loaded backing plate armour was compared with armour that has solid end plate with a view to introducing a more elastic surface that enhances energy absorption properties. The design consists of three major layers of different materials: fibre cement as the first layer; Kevlar as the second; and a spring-loaded backing plate made of steel as the third layer. SolidWorks was used to model the multi-layered armour and ANSYS Workbench Explicit Dynamics and AUTODYN 3D solver were used to simulate the ballistic impact. The simulation involved testing different configurations of the multi-layered structure. Analysis of the effect of the spring wire diameter on the armour's energy-absorbing characteristics was carried out while keeping the overall weight within the acceptable range. The simulation results for the different configurations were compared and the ballistic-resistant armour designed with a spring-loaded backing plate of 0.40 mm spring wire diameter gave the least deformation. The research suggested an enhanced armour performance using embedded elastic material.

Simulation of Supercritical Water Gasification Reaction of Glycerol and Reactor Structure Study

The study established a reactor model with a volume of 500 ml that can withstand high temperature and high pressure, and firstly used the simulation software ANSYS FLUENT 2023R1 to simulate the process of generating H2-rich gaseous products by reacting glycerol in supercritical water at a temperature of 374°C and a pressure of 23 Mpa, and the results showed that the pressure and temperature were uniformly distributed in the fluid domain of the reactor. The results show that the pressure and temperature are uniformly distributed in the fluid domain of the reactor. Secondly, according to the pressure distribution obtained from the simulated reaction, the transient dynamics and thermo-mechanical coupling field analysis were applied to the inner wall of the reactor cavity in ANSYS Workbench to study the stress displacement. Finally, the results of the two analyses are compared to conclude that the pressure field can affect the trend of stress and displacement of the reactor structure, and the temperature field at higher temperatures can increase the values of stress and displacement.

Structural Reliability Analysis of Microsphere Focused Logging Tool Based on Response Surface Method

The push-pull system of microsphere focused logging tool is an important moving mechanism of this type of logging tool. The push-pull system will periodically bear large loads under working conditions and is prone to stress concentration. The structural strength reliability of the push-pull system is related to the logging accuracy and even the success or failure of the logging task. Based on ANSYS workbench software, this paper first conducts modeling and static simulation on the push-pull system of microsphere focused logging tool under working conditions, then conducts sensitivity analysis and experimental design on the basis of this analysis, and then conducts response surface analysis on the key stressed components of the push-pull system according to the analysis results. Finally, six sigma module is used to analyze the reliability of the push-pull system, and the structural strength reliability of the push-pull system is given by the probability distribution table obtained from the analysis. The analysis results show that the maximum equivalent stress occurs on the link arm of the push-pull system under working condition. The strength reliability of the link arm of the push-pull system under current working condition is high, and it can meet the daily logging requirements. However, there is still room for further design optimization.

Structural and Modal Analysis of the Unloading Robot on the Broaching Machine

In order to meet the actual production of a machining company in the low production efficiency, labor intensity, process flow complexity and other real problems, the broaching machine processing upgraded and designed a broaching machine for the production of automatic loading and unloading device. This paper analyzes the layout scheme and workflow of automatic loading and unloading, designs the overall structure of the loading and unloading device and key components, and establishes a three-dimensional model through Solidworks software, and carries out a static analysis of the limit position in the operation process by using the finite element analysis software ANSYS Workbench, and obtains the maximum deformation under the limiting conditions of 0.1129mm, and the maximum stress value of 24.236MPa. The maximum deformation is 0.1129mm and the maximum stress is 24.236MPa. Subsequently, modal analysis is carried out to extract the first 6 orders of intrinsic frequency and corresponding vibration pattern, and harmonic response analysis is carried out on the weak components on the basis of modal analysis, which verifies that the structure complies with the design requirements in terms of strength, stiffness and resonance of the whole machine, and it provides the theoretical basis for the subsequent structural improvement and optimization design.

Modelling, Analysis, Fabrication and Experimental Testing of Leaf Spring Material by Hybrid Composite Materials with Natural Fiber for Electric Vehicle

Present automobiles are running with the help of fuel. But in the future, electricity plays a significant role. The generation upgrading into electricity as the main source. Leaf springs are used for suspension for automobiles. These leaf springs are manufactured with stainless steel material. This is heavy in weight, which is one of the limitations for consuming of fuel. If this material is used in electric vehicle, it consumes more electricity. To overcome this issue the material is replaced with composites. The primary goal of this endeavour is to achieve weight rebates without diminishing in reliability. A parametric study of the leaf spring by varying the three-dimensional parameters will be carried out. Fabrication of the composite specimen is based upon the ASTM standard. Modelling and analysis of composite leaf spring with SOLIDWORKS and ANSYS WORKBENCH software. Epoxy resin and E- glass fibre is reinforced with various fractions of Prosopis Juliflora (Throne powder) composites were falsification by hand layup technique. The fabricated composite material in the form of plate were cut into corresponding profiles as per ASTM standard. The objective is to examine the Stress, Strain, Deformation, Physical property, Mechanical properties, Thermal property of composite leaf spring with that of steel, CFRP.

Design, modelling and simulation of biocompatible poly methyl methacrylate polymer-based inside-mouth support for microphone using finite element analysis in ANSYS workbench software

Design, modelling and simulation of biocompatible poly methyl methacrylate polymer-based inside-mouth support for microphone using finite element analysis in ANSYS workbench software

Experimental and numerical studies on the mechanical characteristics of Timoho fiber epoxy composites with nanofiller addition

AbstractThis study is focused on the investigation of the mechanical characteristics of Timoho fiber (TF) epoxy composites with graphene as the filler material, both experimentally and numerically, for high‐velocity impacts. The composites were prepared by the compression molding process with varying wt.% of graphene. An experimental approach was undertaken to study the behavior of the composites under different wt.% of graphene. To validate the results obtained in the experimental approach, numerical studies were conducted. It was observed that there was an enhancement in the mechanical properties with the addition of graphene. For tensile strength, there was an increase of 33.17% when comparing the controlled sample (0% graphene) and the sample with 2% graphene content. Subsequently, there was an increase of 36.48%, 58.02%, and 29.79% when comparing the controlled samples and samples with 2% graphene, respectively, for flexural, impact, and interlaminar shear strength (ILSS). However, it was observed that after the addition of 2 wt.% of graphene, the mechanical strength decreased due to the agglomeration of graphene inside the composite, which was confirmed using the SEM analysis. For the numerical study, ANSYS workbench was employed, and simulation was conducted using finite element analysis (FEA) for the tensile and flexural test. The numerical findings were found to be reasonably close to the experimental values, with variations ranging from a minimum of 2% to a maximum of 15%. In the design of experiments, Taguchi's approach was used to determine the effect of a variety of parameters on the tensile behavior of the TF epoxy composites.Highlights 2 wt.% of graphene was observed to be the optimum concentration of graphene. The decline in mechanical properties was observed at 3 and 4 wt.% of graphene. Agglomeration of graphene filler in the composite was confirmed using SEM. ANOVA showed that wt.% of graphene made the top contribution to tensile strength. The nanographene‐incorporated TF composites can be used for lightweight applications.