ANSYS Simulation Research Articles

Analysis on the Performance of Designed Fluidized Bed Dryer for Drying Coffee Beans

Drying coffee beans is an important role in the process of making coffee. Most coffee producers dry their coffee beans under the natural sun, but it was found to be time-consuming and depended on the weather conditions. Fluidized bed dryer is found to be the most recent method to dry the coffee beans. However, not many reported on the performance of fluidized bed dryer in coffee drying. In the present research, the quality of the drying process using fluidized bed dryer was investigated by varying the streamline pattern and temperature distribution in the drying chamber. The result was compared with a different temperature and velocity applied. The simulation in ANSYS was conducted with three different velocities of 10 m/s, 20 m/s and 30 m/s with air temperature of 60 °C, 90 °C and 120 °C. The temperature supply was from the inside of the pipe to the end of the drying chamber. The streamline and the temperature distribution were absorbed between the difference of temperature and the velocity difference. The computational analysis of the simulation showed that the increase in velocity resulted in a temperature rise from 46.72°C to 49.04°C within the drying chamber for constant inlet temperature of 60 °C, and on the other hand the velocity in the drying chamber remains constant at average of 3.22 m/s for inlet velocity of 10 m/s despite the increase in temperature.

Comparison of nano-silver solder joints and SAC305 based on ANSYS simulation and life prediction

With the rapid development of microelectronic interconnection technology, the reliability requirements of electronic products are becoming higher and higher. Among them, temperature has the greatest impact on electronic devices. Due to the different coefficients of thermal expansion (CTE) between the many materials of a chip, the inside of a solder joint is subjected to cyclic temperature action. Under the effect of cyclic temperature, the solder joints are subject to internal fracture resulting in the failure of the solder joint. Therefore, it is necessary to find a more reliable material for the solder joint. In this paper, the advantages and disadvantages of pure silver material and low silver material are compared by finite element simulation analysis of nano-silver pure silver material and SAC305 low silver material, and the fatigue life prediction of nano-silveris predicted by a life prediction model. Then, using the Electric Power Research Institute estimation method to estimate the fatigue life of solder joints, the results are compared with those calculated by the finite element method.

Computational fluid dynamics modeling of a wafer etch temperature control system

Next-generation etching processes for semiconductor manufacturing exploit the potential of a variety of operating conditions, including cryogenic conditions at which high etch rates of silicon and very low etch rates of the photoresist are achieved. Thus, tight control of wafer temperature must be maintained. However, large and fast changes in the operating conditions make the wafer temperature control very challenging to be performed using typical etch cooling systems. The selection and evaluation of control tunings, material, and operating costs must be considered for next-generation etching processes under different operating strategies. These evaluations can be performed using digital twin environments (which we define in this paper to be a model that captures the major characteristics expected of a typical industrial process). Motivated by this, this project discusses the development of a computational fluid dynamics (CFD) model of a wafer temperature control (WTC) system that we will refer to as a “digital twin” due to its ability to capture major characteristics of typical wafer temperature control processes. The steps to develop the digital twin using the fluid simulation software ANSYS Fluent are described. Mesh and time independence tests are performed with a subsequent benchmark of the proposed ANSYS model with etch cooling system responses that meet expectations of a typical industrial cooling system. In addition, to quickly test different operating strategies, we propose a reduced-order model in Python based on ANSYS simulation data that is much faster to simulate than the ANSYS model itself. The reduced-order model captures the major features of the WTC system demonstrated in the CFD simulation results. Once the operating strategy is selected, this could be implemented in the digital twin using ANSYS to view flow and temperature profiles in depth.

Eco-friendly materials for brake pad- ANSYS overview

Recently, the awareness of green environment has raised in huge manner with comfort for nature to protect environment in terms of wastage accumulation. Among automotive components, most of the vehicles returned as a scrap vehicle so that the wastes extracted and became harmful due to the chemical treatments of materials. The spare parts of independent components are not much disposes with proper treatment. This exhausts effects the environment under wastages. Here, the brake pad having constituents are not supposed to eco-friendly like asbestos and harmful filler materials. The influence of asbestos materials leads negative impact to environment and surrounding creatures and sustainability to ecological transition. The performance of the brakes pads are completely depends on brake pad and its frictional properties. Based on this, the current study performs about prediction on natural eco-friendly materials used as brake pads by focusing on Eco safe composite mixtures. The prediction is done by simulation in ANSYS with the different eco-friendly materials such as palm kernel fiber, Coconut coir, bamboo, banana peels and so on.

Vibration Modeling and Analysis of a Flexible 3-PRR Planar Parallel Manipulator Based on Transfer Matrix Method for Multibody System

This paper presents the vibration model of a 3-prismatic–revolute–revolute (PRR) planar parallel manipulator (PPM) with three flexible intermedia links, utilizing the linear transfer matrix method for multibody systems (MSTMM). The dynamic characteristics of the PRR PPM are also investigated. The dynamic model of the 3-PRR PPM is derived, and the transfer matrix and transfer equation of each component in the system, as well as the overall transfer equation and transfer matrix of the system are obtained. The vibration characteristics of the whole system are determined using the MSTMM and verified through ANSYS simulation. Furthermore, the relationship between the natural frequencies and the flexible PPM configurations is analyzed under a specific circular trajectory. The results demonstrate that the natural frequency of the system changes constantly with the configurations, and the trends of the first six orders are similar. This novel modeling approach does not require global dynamic equations and is both efficient and accurate. Moreover, it can be easily extended to other parallel manipulators with flexible components.

Overview over the neutral gas pressures in Wendelstein 7-X during divertor operation under boronized wall conditions

During the first test divertor campaign of the stellarator experiment Wendelstein 7-X (Pedersen et al 2022 Nucl. Fusion 62 042022), OP1.2b, 13 neutral gas pressure gauges collected data in different locations in the plasma vessel, enabling a detailed analysis of the neutral gas pressures, the compression ratios and the particle exhaust rates via the turbomolecular pumps in the different magnetic field configurations. In Wendelstein 7-X, the edge magnetic islands are intersected by the divertor target plates and used to create a plasma-wall interface. As the number and position of the magnetic islands varies in different magnetic field configurations, the position of the strike line on the target plates and thus the neutral gas pressure in the subdivertor differs between the configurations. Neutral gas pressures on the order of few 10−4 mbar were measured in the subdivertor region. The highest neutral gas pressure of mbar was obtained in the so-called high iota configuration featuring four edge magnetic islands per cross section. The neutral particle flux through the pumping gaps into the subdivertor volume was provided by EMC3-EIRENE simulations and allowed to analyze the relation between the particle flux entering the subdivertor and the pressure distribution in the subdivertor. Finite element simulations in ANSYS provide a detailed picture of the pressure distribution in the subdivertor volume and agree with the neutral gas pressure measurements in the subdivertor in the standard configuration featuring an island chain of 5 edge magnetic islands. Surprisingly high neutral gas pressures that were not predicted by the simulation were measured in the subdivertor region away from the main strike line for discharges in the most used magnetic configuration, the standard configuration. While the pressure ratio between the two sections of the subdivertor volume, the low and high iota section is 0.06 in high iota configuration, a ratio of 2–5 was obtained in the other configurations, indicating significant particle loads and exhaust rates on the high iota section of the subdivertor in magnetic configurations with the main strike line on the low iota divertor targets.

Study on the acoustic characteristics of a heavy-duty gas turbine combustor

The acoustic characteristics of combustor are an important theoretical basis for determining whether a gas turbine will undergo thermoacoustic coupled oscillatory combustion. In this paper, the acoustic numerical model of a heavy-duty gas turbine combustor is established and its acoustic characteristics are studied using ANSYS simulation software. The results show that: 1) the acoustic pressure oscillation in the chamber primarily appears as the longitudinal mode below 705 Hz, while above 870 Hz, the transverse mode appears. 2) the effect of temperature on the acoustic natural frequency of the chamber enhances with the order of the acoustic mode. 3) the acoustic frequency of each order of the combustor varies considerably at low load conditions, and no longer varies when the gas turbine load is higher than 80 % rated power. 4) the variation of acoustic frequency with gas turbine load can be fitted by a third-order polynomial, and the acoustic frequency is proportional to the first and third orders.

Some investigations on experimental and simulation results of EV Battery pack to provide ideal operating temperature for battery safety

The battery also referred to as a chemical energy storage device—generates the required electrical energy. A cell is the basic component of a battery that produces energy. The significance of personal safety of person and vehicle service security has brought attention to battery thermal safety issues in recent years. To meet the anticipated problems and assure battery safety, the most recent innovations in battery thermal management (BTM) are being done. With a heat transfer intensify technique, the BTM technology improves battery safety while ensuring battery operation performance based on the battery's thermo-kinetic, mechanical, and electrochemical characteristics under both normal as well as abnormal operating settings. It is also crucial to prevent overheating and provide the optimal operating temperature for safe operation. Hence, creating a BTM system that is both secure and reliable. In this investigation, thermal calculations based on experimental data were performed and the outcomes of the ANSYS simulation were compared. It was found that the cell's highest temperature in ANSYS was 31.6°C, which was close to cell's average temperature. This temperature was in good agreement with the temperature obtained during actual testing (31.6°C). Key Word: Battery Thermal Management System, Li-ion batteries, Battery components.

Flexible horizontal piezoelectric energy generator for sea wave applications

Energy harvesting from the environment becomes a valuable technology, especially for sea wave applications, in which it usually ends up wasted despite its potential to be harvested. Due to its wide availability and high energy density, piezoelectric energy harvesting (PEH) is becoming popular for flexible energy harvesting. This paper presents a flexible horizontal piezoelectric (FHP) energy harvester to harvest energy from the surface of sea wave. The harvester is made of bimorph piezoelectric devices; they are utilised to amplify and convert the collected mechanical vibrations into electrical power. A finite element model is established from ANSYS simulations to solve the iteration method by generating resonance frequency (fr). Then, Taguchi method, SN ratio and the ANOVA approach were used by considering the input variable of fr to estimate the optimum performance through control factors; number of blade, length and thickness. From the performance test result, it is proven that the higher numbers of blade including length, and minimum numbers of thickness significantly improve the significant level, α = 0.05% of ANOVA. Three prototypes are developed with approximate body dimensions through the resonance frequency perform and generate a 160.3 Hz on blade dimensions of 10 × 300 × 0.2 mm, with a piezoelectric (PZT) on its surface. This particular study shows that the potential of output power is generated from sea wave surface through a significant relationship between length, thickness, and blade design. This research develops a novelty for energy harvesting from flexible piezoelectric generator on sea wave application that could be easily install on offshore platform.

Investigating the Manufacturing Process of Heat-Treated Nb3Sn-CICC Conductor for CFETR CSMC Modules

The center solenoid model coil (CSMC) of the China fusion engineering test reactor (CFETR) requires a high heat treatment temperature of 650 °C, which would destroy the insulation layer by carbonization and cause coil failure. To avoid this, using the manufacturing technology and routine process of the ITER center solenoid coil as a reference, in this article, a solution is introduced that is applied for manufacturing the CFETR CSMC module. The coil is heat treated before insulation and after winding. A single turn of the heat-treated coil is separated and the wrapping turn insulation is applied, and then the separated layers are reversed back into the integrated coil. To manufacture the integrated coils, the heat-treated coils are molded. After heat treatment, the interlayer separation distance of the Nb <sub xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">3</sub> Sn cable-in-conduit conductor in the coil should satisfy the allowable strain range of the superconductor, which is crucial for designing the rotational support structure of the interlayer separation. In addition, to achieve the accurate final shape of the coil and meet the design requirements, as well as to ensure coil contour accuracy after layer by layer separation, the antideformation ability of the coil mold is a key research topic. Herein, mechanical properties of the key components were optimized and numerical calculations and ANSYS simulations were used for statistical analyses. Results from the analyses indicated that the equivalent stress on the device is less than the maximum permissible stress of the raw material. The device was manufactured and compared with a design mold. The overall deformation error was <5%, movement error of the electric frame was <2%, rotation error of rotating was less than ±1° per 360°, levelness between the upper and lower platform was <1 mm, and motion error was less than ±1 mm per 100 mm. These results demonstrated the optimized structure design of the device. In the as-obtained device, the coil could separate a single turn and wrapping turn insulation could be applied. Parameters of the manufactured coil satisfied all the CSMC design requirements; these results indicate that the proposed device is suitable for manufacturing the CFETR CSMC module coil.

A textured surface with oil inflow and outflow function designed for starved lubrication

This study presents a surface, referred as ‘pocket-textured surface’, which combines traditional surface texture with the oil storage pocket that can improve the tribological performance of line contact under extremely starved lubrication conditions. The pocket-textured surface has up to 48% lower friction coefficient than the untextured surface with the same little lubricant supply. Tribological experiments were carried out to explore the tribological behavior of pocket-textured surfaces with different ratios of texture hole depth and oil pocket depth under different loads and sliding speeds. In addition, a high-speed camera observed the lubricant inflow and outflow, and Ansys simulation calculated the deformations and pressures of the pocket-textured surface.

Finite element modeling of straight pipeline with partially attached viscoelastic damping patch based on variable thickness laminated element

To successfully implement the viscoelastic damping patch (VDP) for vibration reduction of the straight pipeline, it is necessary to perform dynamic modeling to guide vibration reduction design. The nonlinear vibration characteristic of the straight pipeline with partially attached VDP is studied by the FEM. A modeling method of laminated shell elements with variable thickness is proposed. Additionally, the local coordinate transformation is executed to facilitate the integration calculation of each layer. The nonlinear dynamic equation of the straight pipeline with VDP is established by considering the frequency dependence of VDP and the non-uniform continuous variable stiffness distribution of the clamp. The Vector Iteration method based on Improved Approximate Eigenvalue (VIM/IAE) is proposed to solve the nonlinear eigenvalues further. The rationality of the FE model is verified by constructing an experimental test system and compared with the ANSYS simulation and references. Finally, the vibration reduction mechanism of the clamp-straight pipeline with partially attached VDP considering frequency dependence is analyzed under different nonlinear iterative algorithms, VDP parameters (thickness, elastic modulus, and loss modulus), and boundary stiffness.

Heat Dissipation Design of Power Battery Module Based on Air Cooling - Semiconductor Refrigeration

In order to ensure that the soft package power battery can work stably for a long time under the condition of large discharge rate, the heat dissipation of the soft package power battery module is optimized based on the semiconductor thermoelectric effect. Based on the establishment of a traditional air-cooled heat dissipation model and air-cooled-thermoelectric cooler heat dissipation model and ANSYS simulation comparison, the maximum temperature difference, maximum temperature and average temperature of the battery module are analyzed. The optimized simulation results show that the temperature control of the battery module by air cooling-thermoelectric cooler can effectively reduce the temperature difference and the maximum temperature of the battery module. The method significantly improves the heat dissipation performance of the battery module.

Simulation-Based Reliability Design Optimization Method for Industrial Robot Structural Design

Robots are main elements in Industry 4.0. Research on the design optimization of robots has a great significance in manufacturing industries. There inevitably exist various uncertainties in robot design that have an important influence on the reliability of robots. At present, the design optimization of robots considering the uncertainties is mainly focused on joints design and trajectory optimization. However, for the structural design of robots, deterministic design optimization still plays a leading role. In this paper, a simulation-based reliability design optimization method is proposed to improve the reliability of robots’ structural design. In the proposed method, the Latin hypercube sampling (LHS), computer simulation, response surface method (RSM) and SORA (Sequential Optimization and Reliability Assessment) algorithm are integrated to complete the structural design of the robot. Firstly, samples of the uncertainty design variables were obtained by LHS, and then, the reliability performance constraint functions were firstly constructed through the RSM in which the joint simulation of MTLAB and ANSYS was adopted. Afterwards, the reliability design optimization model was established on the basis of the probabilistic reliability theory. At last, the SORA algorithm was employed to realize the optimization. The design optimization problems of the big arm and the small arm of a 6 Kg industrial robot were considered to verify the proposed method. The results showed that the weights of the big arm and the small arm were, respectively, reduced by 7.73% and 25.70% compared with those of the original design, and the design was more effective in ensuring the reliability requirements compared with the deterministic optimization. Moreover, the results also demonstrated that the proposed method has a better computational efficiency compared with the reliability design optimization of the double-loop method.

Three-dimensional dynamic model of the curved pipe based on the absolute nodal coordinate formulation

Due to the lack of advanced models and analytical methods, the study of pipe conveying fluid usually only considers the in-plane vibration of straight pipe. In order to fully understand the dynamic characteristics of curved pipe, it is necessary to establish the three-dimensional (3D) dynamic model. However, there are still few 3D modeling methods for the curved pipe. In this paper, based on the absolute nodal coordinate formulation (ANCF), a 3D finite element model for the curved pipe is developed. The nonlinear dynamic equations of the pipe system are derived by using the extended Lagrange equations. The natural frequencies and modes are calculated by linearizing the equations. The established model and the adopted method are verified through the comparison with relevant literature and ANSYS simulation. Furthermore, the effects of the relevant parameters on the natural vibration of curved pipe are discussed. The in-plane and out-of-plane natural vibration characteristics of curved pipe are compared and summarized for the first time. Finally, the advantages of the proposed model are outlined by the comparison with the planar dynamic model. The results provide new information about the effect of initial curvatures on the spatial vibration characteristics of pipes. In conclusion, this paper provides a novel dynamic model for studying the spatial vibration of the curved pipe. In the meantime, the results of this paper can also can guide for the research of the vibration of curved pipes in engineering.

Experimental Studies and Numerical Simulations of FRP Poles Failure in the Area of Inspection Hole

Glass fiber-reinforced polymer (GFRP) utility poles are becoming more widespread in European countries. To ensure the integrity and safety of poles, it is necessary to carefully examine their structural features. The purpose of this paper is to present the numerical model of a column made with the engineering simulation software ANSYS and to compare the experimentally determined values of the stresses that lead to column failure close to the inspection hole with the results obtained using the numerical model. The critical buckling and failure loads for GFRP poles, as well as the associated modes of failure, were correctly predicted by the finite element method used in this study. Failure occurred in the middle of the inspection hole's longer edge at a stress level of 220-250 MPa. A comparison of the stress using the ANSYS simulation software that led to the destruction of the column with those measured experimentally using strain gauges revealed a good agreement between their values.

The Behavior of RC Beams Strengthened with Steel Fiber Concrete Layer by ANSYS Simulation

In this study, a double-layer reinforced concrete beam structure was created for the purpose of repairing reinforced concrete beams by pouring a layer of concrete on top of the reinforced concrete beam and then adding fibers to the concrete. Take into consideration the bearing capacity of these double-layer concrete beams as well as the effects that the input parameters have on the stress strain, the propagation of cracks in reinforced concrete beams. The study looks at double-layered reinforced concrete beams, with the steel fiber concrete placed on top of the one containing the normal concrete. This investigation led to the following relationships: load-compressive stress, tensile stress, and vertical displacement at the midpoint of the beam span, as well as a diagram showing how cracks spread in the beams. After getting the experimental results and comparing them with an ANSYS simulation, the diagram was used to figure out the loads at which the beams start to look cracked and the loads at which the beams are damaged. This study investigated the following six cases: how the addition of SFs affects the properties of concrete, the spacing of the stirrups at the ends of the beam should be looked into to see what effects it might have, how the number of tensile steel bars in the beam affects its properties, how the diameter of tensile steel bars affects their properties, how the diameter of compressed steel bars affects the results, and how the thickness of the SFC layer affects the properties of the material. Also, the things that were mentioned would have a big effect on how these double-layer beams in the design work.

Simulation of A Solar Drier for Iroko Wood (Chlorophora Excelsa) in A Tropical Environment

In a previous study conducted by Simo Tagne to designing a solar dryer based on mathematical equations for iroko wood in Cameroon, Africa. However, there is no complete simulation of the drying process on the tool, resulting in the lack of detailed elaboration of the iroko wood drying process. The purpose of this study is to simulate in detail the drying process on the tool using an ANSYS simulation. The model used in this simulation still uses the same mathematical model that has been studied before. This research begins by setting up the ANSYS application with the previous mathematical model, environmental conditions, and tool specifications. Furthermore, simulations are carried out using the ANSYS application with measurements of pressure, temperature, velocity and mass transfer. From this simulation obtained results for the distribution of pressure, temperature, velocity, and mass transfer. From all these distributions, it is sufficient to describe the drying process of the tool according to the mathematical model that has been studied previously.

Numerical Simulation Study of Multi-Field Coupling for Laser Cladding of Shaft Parts.

Since shaft parts operate under harsh environments for a long time, many critical parts suffer from corrosion, wear and other problems, leading to part failure and inability to continue in service. It is imperative to repair failed parts and increase their service life. An orthogonal experimental scheme is designed to numerically simulate the process of laser cladding of Inconel 718 alloy powder on 4140 alloy structural steel based on the ANSYS simulation platform, derive the relationship equation of cladding layer thickness according to the heat balance principle, establish a finite element model, couple three modules of temperature field, stress field and fluid field, and analyze different modules to realize the monitoring of different processes of laser cladding. The optimal cladding parameters were laser power 1000 W, scanning speed 15 rad/s, spot radius 1.5 mm, thermal stress maximum value of 696 Mpa, residual stress minimum value of 281 Mpa, and the degree of influence of three factors on thermal stress maximum value: laser power > spot radius > scanning speed. The pool in the melting process appears to melt the "sharp corner" phenomenon, the internal shows a double vortex effect, with a maximum flow rate of 0.02 m/s. The solidification process shows a different shape at each stage due to the different driving forces. In this paper, multi-field-coupled numerical simulations of the laser cladding process were performed to obtain optimal cladding parameters with low residual stresses in the clad layer. The melt pool grows and expands gradually during melting, but the laser loading time is limited, and the size and shape of the melt pool are eventually fixed, and there is a vortex flowing from the center to both sides of the cross-section inside the melt pool, forming a double vortex effect. The solidification is divided into four stages to complete the transformation of the liquid phase of the melt pool to the solid phase, and the cladding layer is formed. The multi-field-coupled numerical simulation technique is used to analyze the temperature, stress and fluid fields to provide a theoretical basis for the residual stress and surface quality of the clad layer for subsequent laser cladding experiments.

Understanding and improving temporary road sign stability

Temporary road signage is used throughout road networks to regulate traffic and provide warnings to road users. Wind and other factors induce frequent falling of temporary road signage and are a major road safety concern that needs to be addressed. The main aim of this paper was to gain an understanding of temporary road sign stability in the presence of passing road trains and investigate the possibility of stabilising temporary road signage through appropriate design modifications. Simulations and experimental trials were carried out to assess the stability of current temporary road signs used in the industry. This analysis used Ansys Fluent to simulate fluid dynamics in order to infer road sign stability. A field experimental trial was performed in Western Australia’s Pilbara Region using a modified temporary road sign developed based on the outcome of the Ansys simulation. The findings from the simulations showed that the current design is unstable and highly prone to wind induced failure. The simulations suggest that road train transit at 100 km/h is capable of inducing approximately 8 m/s wind velocity in the proximity of the sign, which is greater than that permissible for a rigid sign with no leg mobility. Field trials showed that the modified sign remained stable at 1.2 m from the edge line although it was still prone to falling over at closer distances.