Design Of Exhaust Fan By Using ABS Plastic Material

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CHAPTER-1
INTRODUCTION
1.1 EXHAUST FAN
Exhaust fans are appliances used to relieve enclosed spaces from excessive
heat or polluted air. They are quite essential for well-being, as they ensure retention of
freshness, in the air, for breathing.
In Indian context, exhaust fans are no less important. They mostly find use in
kitchens and bathrooms in our country. Many types of emissions are released from
spicy food that is cooked on daily basis in kitchens.
Bathrooms are not free from moisture and People, who earlier did not feel the
need to buy exhaust fans in India, hold a different opinion now.
MECHANISM OF EXHAUST FAN
An exhaust fan runs on electricity. The motor operated fan works when the
electric current passes through the system and make the blades move.
The blades help in drawing excessive heat or smoke from the air and vent it
out. In turn cooler air fills the area. Thus recycling of air takes place. In other words,
the blades rotate till the temperature stabilizes and air becomes cooler in a particular
area.
The fans are generally fitted at the top of walls, nearer to the ceilings for
maximum effect. This is done to draw significant amount of heat and release it out,
since hot air rises upwards. Many exhaust fans have Thermostat technology, which
enables the motor to run automatically, when a room reaches high temperature.
In Kitchens
Kitchens get overheated quickly due to various fumes and smokes that arise
out of cooking processes. This gases needs to be vented out to provide circulation of
fresh and cooler air inside.
The air borne irritants, humidity, are also removed through these fans. The
pollutants produced by gas and electric stoves, cooking greases, etc. may contribute to
respiratory and cardiac problems and this appliances may avert arising of such
problems.

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In Bathrooms
In Bathrooms lots of water is released, whether in form of hot or cool
water. In case of Sauna Bath, steam is emitted in high amount. The moisture
remnants in a bathroom result in growing of molds which have their negative
effects too. Various germs are also cleansed from our body, the effects of
which may be reduced using these fans.
Overall Residential uses
Exhaust fans are generally beneficial when used in rooms which have poor
ventilation. The warm effect and staleness of air is reduced indoors with their use. It
also helps in removing odors from room, thus helping to create a breathable
atmosphere.
Indoor air pollutants cause problems like allergy, irritation of exposed areas of
body, breathing problems, etc. which may also give rise to major health problems, and
so their existence cannot be ignored.
Commercial Use
Exhaust fans are also used in commercial workplaces to bring coolness and
make them free from stagnant air.They are generally larger and more powerful than
those used for residential purposes. Places like commercial kitchen, warehouses,
stores, garages etc. find commercial fans useful.
In the present scenario, where energy efficiency is regarded as an important
factor while buying any electrical appliance, exhaust fans serve good. Many online
shopping sites have emerged, apart from physical stores which has increased the rate
with which people buy exhaust fans in India.
Air pollution rate in indoor areas is far higher than outdoors in developing
countries, as per recent studies. Awareness about the need to practice caution from
detrimental effects of such pollution could also be taken as a factor behind rising sales
figure of such fans.

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Ceiling exhaust fan
With a perfect mix of of sturdiness and powerful performance, these fans can
efficiently suck out heat and hot air and dispel it outside. Designed to give the
optimum performance, keep unpleasant odors at bay when you install a ceiling
exhaust fan. You can keep your rooms fresh and alive with superior quality ceiling
exhaust fans from top brands.
Industrial exhaust fan
This type of exhaust has a highly energy efficient motor for a smooth and
vibration-free operation. To keep workers safe and comfortable, air cleaners and
exhausts are of utmost importance.
These are some of the main types of exhaust fans that are available today
besides other electrical appliances like Air Conditioner, AC Spare Parts, Ceiling Fans,
Geysers, Miscellaneous Fans, Table & Pedestal Fan, Tower AC, Wall Fans etc.
Usually people opt for the quietest and the most energy efficient fan to meet their
needs. You can choose the exhaust fan that best suits your needs and purpose and opt
for the same accordingly.
An exhaust fan may be extremely beneficial in ways which you would never
have thought possible. In fact, very few people are aware that “stale air” may have a
detrimental effect on persons cooped up in the same house. A lack of air flow usually
results in problems such as mildew, mould and even damage to furniture. Moreover, it
could also result in minor illnesses, such as allergies, headaches or even asthma.
Therefore, having an exhaust fan will greatly help in limiting these problems, since it
would recycle the air we live in everyday. Various types of exhaust fans are available,
each with their own characteristics.
1.2 DIFFERENT TYPES OF EXHAUST FANS
Wall Mounted Exhaust Fans
These types of fans are ideal if you do not wish to spend a lot of time devising
and planning your fan’s installation. A wall mounted fan is installed to an external
wall of your house, and enables the air inside to exit straight through the fan itself.

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Exterior Exhaust Fans
Similar to wall-mounted fans, these type of fans actually pull out the air inside
the building and expel it outside. Exterior exhaust fans are particularly suited to those
who do not want any noise issues, since in this case any noise emitted from the fan
would be outside of the house.
Ceiling Mounted Exhaust Fans
If you have an upstairs room in need of better air flow, a ceiling mounted fan
is your best bet. These are mounted from the ceiling of a room, and they remove the
air inside through a hole in the ceiling. As such, more often than not a ceiling
mounted fan makes use of a hole in a building’s attic. Inline Exhaust Fans
In case you wish to install a fan in a room which is difficult to ventilate, you
should consider an inline exhaust fan. These fans are mounted in between the ducting,
so that the bad air is expelled through the ducts.
Exhaust Fans Including Lights
Apart from doing what a normal exhaust fan does, these type of combo fans
can also lighten up your ventilated area. This is a great way of making the fan more
innocuous, since it would blend in the atmosphere as if it was just another light
source.
1.3 HOW TO INSTALL AN EXHAUST HOOD FAN
 Drill
 Exhaust Hood Fan
 Screws
 Screwdrivers (Flat and Cross)
 Wire Nuts
 Nut Driver
 Voltmeter

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CHAPTER: 2
LITERATURE SURVEY
CHAPTER: 2
LITERATURE SURVEY

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A fan that moves air out of an enclosure. Fans located in the wall or ceiling
that exhaust air, odors and moisture to the outside. Probably the simplest meaning of
an exhaust fan is actually a fan that pushes air off a bounded space, particularly from
the interior of a home. These kinds of fans are supposed to pull the hot air from a
house, of which it'll then normally be vented into the attic, where it is then forced out
of the home entirely via different vents. The push-pull pressure that results from this
kind of system creates the power to draw in cold air from the outside when the house's
windows are open.
This type of system is a good way to quickly cool the home, or any other sort
of enclosed building it is also an amazing cost-effective alternative to utilizing an air
conditioner. One other added benefit is that these fans are energy efficient, are smaller
in size, and are generally quiet. Exhaust fans are available in two varieties: ceiling
mounted and ducted; there is also a 'do-it-yourself' set up, for those home owners who
are handy-men. When thinking of the house, a good home ventilation system will
include both a cooking area exhaust fan and a toilet exhaust fan. On the subject of the
restroom, bathroom exhaust fans are made to be quite powerful; they've got a
particular use as to ridding the area of odors, or ridding the location and the rest of the
house, of humid air.
With these kinds of fans, it's important however, to ensure they're correctly
installed, as the result of a terrible installation can result in the presence of mould, and
coincidentally, the rotting of wood. Putting in the fan vent via the roof of a home is
often the most effective course of action .the kitchen type will easily rid the kitchen
area of both its different odors as well as its smoke. It's important that kitchen exhaust
fans are venting air directly outside of the home, not only to get the most out of the
fan, but additionally for the safety of those who stay inside the home. Kitchens
typically come with a standard exhaust fan, however these standard fans re-circulate
the air they take in, to then direct it higher within the area, instead of extracting it out
of the room completely.

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CHAPTER-3
TYPES OF MATERIALS
CHAPTER-3
TYPES OF MATERIALS

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3.1 MATERIAL TYPES
One of the major innovations of the past century has been the introduction and
wide adoption of plastics for many day-to-day applications that previously relied on
traditional materials like metal, glass, or cotton. Plastics have revolutionized many
industries for a number of different reasons to include the fact that they resist
environmental degradation over time, are generally safe for human beings, are
economical and widely available, and are produced with a wide variety of material
properties that allow adaptation to many different applications. Here is our list of the
top 11 plastics the modern world simply cannot do without:
3.1.1 Polyethylene terephthalate (PETE or PET)
PET is the most widely produced plastic in the world. It is used predominantly as a
fiber (known by the trade name “polyester”) and for bottling or packaging. For
example, PET is the plastic used for bottled water and is highly recyclable. Three
words or short phrases to describe the major benefits of Polyethylene relative to other
plastics and materials would be
 Wide applications as a fiber (“polyester”)
 Extremely effective moisture barrier
 Shatter proof
3.1.2Polyethylene (PE)
There are a number of different variants of polyethylene. Low and high
density polyethylene (LDPE and HDPE respectively) are the two most common and
the material properties vary across the different variants.
1. LDPE: LDPE is the plastic used for plastic bags in grocery stores. It has high
ductility but low tensile strength.
2. HDPE: A stiff plastic used for more robust plastic packaging like laundry
detergent containers as well as for construction applications or trash bins.

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3. UHMW: Extremely strong plastic that can rival or even exceed steel in
strength and is used is for applications like medical devices (e.g. artificial
hips).
3.1.3Polyvinyl Chloride (PVC)
Polyvinyl Chloride is perhaps most well known for its use in residential and
commercial property construction applications. Different types of PVC are used for
plumbing, insulation of electrical wires, and “vinyl” siding. In the construction
business PVC pipe is often referred to by the term “schedule 40” which indicates the
thickness of the pipe relative to its length.
Three words or short phrases to describe the major benefits of PVC relative to
other plastics and materials would be
 Brittle
 Rigid (although different PVC variants are actually designed to be very
flexible)
 Strong
3.1.4 Polypropylene (PP)
Polypropylene is used in a variety of applications to include packaging for
consumer products, plastic parts for the automotive industry, special devices
like living hinges, and textiles. It is semi-transparent, has a low-friction surface,
doesn’t react well with liquids, is easily repaired from damage and has good electrical
resistance (i.e. it is a good electrical insulator).
3.1.5 Polystyrene (PS)
Polystyrene is used widely in packaging under the trade name “styrofoam.” It
is also available as a naturally transparent solid commonly used for consumer
products like soft drink lids or medical devices like test tubes or petri dishes.
One short phrase to describe the major benefits of Polystyrene relative to other
plastics and materials.

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3.1.6 Polylactic Acid (PLA)
Polylactic Acid is unique in relation to the other plastics on this list in that it is
derived from biomass rather than petroleum. Accordingly it bio-degrades much
quicker than traditional plastic materials.
Two words or short phrases to describe the major benefits of Polylactic Acid
relative to other plastics and materials would be
 Biodegradable
 DIY 3D Printing (compare PLA to ABS)
3.1.7 Polycarbonate (PC):
Polycarbonate is a transparent material known for its particularly high impact
strength relative to other plastics. It is used in greenhouses where high transmissivity
and high strength are both required or in riot gear for police.
Two words or short phrases to describe the major benefits of Polycarbonate relative to
other plastics and materials would be
 Transparent
 High Strength
3.1.8 Acrylic (PMMA):
Acrylic is best known for its use in optical devices. It is extremely transparent,
scratch resistant, and much less susceptible to damaging human skin or eye tissue if it
fails (e.g. shatters) in close proximity to sensitive tissue.
Two words or short phrases to describe the major benefits of Acrylic relative
to other plastics and materials would be
3.1.9 Acetal (Polyoxymethylene - POM)

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Acetal is a very high tensile strength plastic with significant creep resistant
properties that bridge the material properties gap between most plastics and metals. It
is known for high resistance to heat, abrasion, water, and chemical compounds.
Additionally, Acetal has a particularly low coefficient of friction which combined
with its other characteristics makes it very useful for applications that utilize gears.
One short phrase to describe the major benefits of Acetal relative to other
plastics and materials would be
 Low Friction
3.1.10 Nylon (PA):
Nylon is used for a variety of applications to include clothing, reinforcement
in rubber material like car tires, for use as a rope or thread, and for a number of
injection molded parts for vehicles and mechanical equipment. It is often used as a
substitute for low strength metals in applications like car engines because of its high
strength (relative to other plastics), high temperature resilience, and high chemical
compatibility.
Two short phrases to describe the major benefits of Nylon relative to other
plastics and materials would be:
 High Strength
 Temperature Resistant
This list really wouldn’t be complete without ABS. ABS is the plastic we use
most often to rapid prototype on a day-to-day basis.
3.2 ABS (Acrylonitrile Butadiene Styrene)
ABS has a strong resistance to corrosive chemicals and physical impacts. It is
very easy to machine, is readily available and has a low melting temperature making
it particularly simple to use in injection molding manufacturing processes or 3D
printing.

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FIG3.1 LEGO TOYS MADE FROM ABS PLASTIC
Four short phrases to describe the major benefits of ABS relative to other plastics and
materials would be
 Impact Resistant
 Readily Available
 Simple To Manufacture
 #1 Material For 3D Printing
No matter what the application is there are different plastics with the right material
properties to suit the requirements. If you’re looking for the right plastic for your
application we can help. We have been creating plastic prototypes for more than 30
years and can help you or your organization make your idea a reality. A composite
material is one composed of two or more components combined in a way that allows
the materials to stay distinct and identifiable. Both components add strength to a
composite, and the combination often compensates for weaknesses in the individual
components. Composites are not the same as alloys, such as brass or bronze. Alloys
are formed in such a way that it is impossible to tell one component from the other.
Some common composite materials include concrete, fiberglass, mud bricks, and
natural composites such as rock and wood.

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3.2.1 PROPRTEIES OF ABS PLASTIC
Chemical Resistance of Plastic
Some chemicals may react with a given polymer by changing its color with
out affecting its mechanical capabilities, while other materials may actively degrade
or dissolve it. Manufacturer chemical compatibility data should be reviewed for each
given chemical compound. Chemical Compatibility data may be available upon
request.
Dielectric Strength of Plastic
Dielectric Strength is displayed as volts per mil (1/1000 inch). The dielectric
strength of an insulating material is equal to the maximum electric field
strength/stress that it can withstand without experiencing failure of its insulating
properties(without breaking down). ATSM D-149
Flexural Strength of Plastic
Flexural Strength is defined as a material's ability to resist deformation under
load. The flexural strength represents the highest stress experienced within a given
material at its moment of rupture. It is measured in terms of stress by applied force in
pounds per square inch. ATSM D-790
Light Transmission of Plastic
This document lists both Visible and UV light transmission characteristics. It
refers to the amount of light a material allows through it. UV light transmission is
based on the nm range of UV light transmitted. Visible light transmission is the
amount of visible light transmitted based on the D65 Illuminant scale where 100%
transmission allows through 6500k lumens.
Heat Deflection Temperature of Plastic
Heat Deflection Temperature is the temperature at which a material deforms
under a specified load. The temperature is increased at 2 °C or 35.6°F /min until the
specimen deflects 0.25mm/.01in. The deflection temperature test results are a useful
measure of relative service temperature for a polymer when used in load-bearing

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parts. However, the deflection temperature test is a short-term test and should not be
used alone for product design-ATSM D-149.
Izod Impact Test (Notched) of Plastic
The IZOD Impact Test determines the impact resistance of a sample material.
This test involves an arm held at a specific height, which when released hits the
sample and breaks it. From the energy absorbed by the sample, its impact energy is
determined. A notched sample is used to determine impact energy and notch
sensitivity indicating the energy required to break the notch. ATSM D-256
Maximum Continuous Operating Temperature of Plastic
Maximum operating temperature is the highest temperature at which a
material will maintain its mechanical stability.
Rockwell Hardness Scale of Plastic
The Rockwell Scale is a general method for measuring the bulk hardness of
metallic and polymer materials. Although hardness testing does not give a direct
measurement of any performance properties, hardness of a material correlates directly
with its strength, wear resistance, and other properties. Rockwell hardness testing is
an indentation testing method
Tensile Strength of Plastic
Tensile strength (Ultimate Tensile Strength) is calculated as the maximum
stress that a material can withstand while being stretched or pulled before
failing/tearing/breaking. The listed values are measured in pounds per square inch.
ATSM D-638
UV Resistance of Plastic
UV Resistance refers to a material’s ability to resist degradation from
absorbing UV radiation. Materials that are not UV stable will change both in
appearance and molecular structure when exposed to UV, and over time can become
brittle, crack, change , color, warp etc

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ABOUT MATERIAL ABS PLASTIC
Acrylonitrile Butadiene Styrene (ABS) –ABS is a thermoplastics polymer
family. This material is comes from acrylonitrile, butadiene and styrene. Usual
compositions are about half styrene with the balance divided between butadiene and
acrylonitrile. Considerable variation, possible resulting in many several grades of
acrylonitrile butadiene styrene with a wide range of features and applications.
In addition, many blends with other materials such as polyvinylchloride,
polycarbonates and polysulfoneshave been developed. Acrylonitrile Butadiene
Styrene (ABS) polymer was first discovered during World War II when its basis,
SBR, was used for alternatives to rubber. In the early 1950s acrylonitrile butadiene
styrene polymers first available material to get the good properties of both
polystyrene and styrene acrylonitrile.
3.2.2 Features
 Flame Retardant High
 Heat Resistance
 Good Impact Resistance
 High Impact Resistance
 High Flow
 General Purpose
 Good Flow
 Good Process ability
 High Gloss
 Good Dimensional Stability
3.2.3 Uses
 Automotive Applications
 Electrical/Electronic Applications
 General Purpose
 Housings
 Appliances
 Business Equipment

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3.2.4 Disadvantages
 Limited weathering resistance
 Moderate heat, moisture and chemical resistance
 Relatively high cost
 Flammable with high smoke generation
3.3 ALUMINIUM ALLOYS
Aluminum alloys; see spelling differences) are alloys in which aluminum (Al)
is the predominant metal. The typical alloying elements are copper, magnesium,
manganese, silicon, tin and zinc. There are two principal classifications,
namely casting alloys and wrought alloys, both of which are further subdivided into
the categories heat-treatable and non-heat-treatable. About 85% of aluminum is used
for wrought products, for example rolled plate, foils and extrusions. Cast aluminum
alloys yield cost-effective products due to the low melting point, although they
generally have lower tensile strengths than wrought alloys. The most important cast
aluminum alloy system is Al–Si, where the high levels of silicon (4.0–13%)
contribute to give good casting characteristics. Aluminum alloys are widely used in
engineering structures and components where light weight or corrosion resistance is
required
Aluminum alloys typically have an elastic modulus of about 70 GPa, which is
about one-third of the elastic modulus of most kinds of steel and steel alloys.
Therefore, for a given load, a component or unit made of an aluminium alloy will
experience a greater deformation in the elastic regime than a steel part of identical
size and shape. Though there are aluminium alloys with somewhat-higher tensile
strengths than the commonly used kinds of steel, simply replacing a steel part with an
aluminium alloy might lead to problems.
With completely new metal products, the design choices are often governed
by the choice of manufacturing technology. Extrusions are particularly important in
this regard, owing to the ease with which aluminium alloys, particularly the
Al–Mg–Si series, can be extruded to form complex profiles.
In general, stiffer and lighter designs can be achieved with Aluminium alloy
than is feasible with steels. For instance, consider the bending of a thin-walled tube:

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the second moment of area is inversely related to the stress in the tube wall, i.e.
stresses are lower for larger values. The second moment of area is proportional to the
cube of the radius times the wall thickness, thus increasing the radius (and weight) by
26% will lead to a halving of the wall stress. For this reason, bicycle frames made of
aluminium alloys make use of larger tube diameters than steel or titanium in order to
yield the desired stiffness and strength. In automotive engineering, cars made of
aluminium alloys employ space frames made of extruded profiles to ensure rigidity.
This represents a radical change from the common approach for current steel car
design, which depend on the body shells for stiffness, known as uni body design.
Aluminium alloys are widely used in automotive engines, particularly
in cylinder blocks and crankcases due to the weight savings that are possible. Since
aluminium alloys are susceptible to warping at elevated temperatures, the cooling
system of such engines is critical. Manufacturing techniques and metallurgical
advancements have also been instrumental for the successful application in
automotive engines. In the 1960s, the aluminium cylinder heads of the Corvair earned
a reputation for failure and stripping of threads, which is not seen in current
aluminium cylinder heads.
Alloy Categories: It is convenient to divide aluminum alloys into two major
categories: wrought compositions and cast compositions. A further differentiation for
each category is based on the primary mechanism of property development. Many
alloys respond to thermal treatment based on phase solubility’s. These treatments
include solution heat treatment, quenching, and precipitation, or age, hardening. For
either casting or wrought alloys, such alloys are described as heat treatable. A large
number of other wrought compositions rely instead on work hardening through
mechanical reduction, usually in combination with various annealing procedures for
property development. These alloys are referred to as work hardening. Some casting
alloys are essentially not heat treatable and are used only in as-cast or in thermally
modified conditions unrelated to solution or precipitation effects. Cast and wrought
alloy nomenclatures have been developed. The Aluminum Association system is most
widely recognized in the United States. Their alloy identification system employs
different nomenclatures for wrought and cast alloys, but divides alloys into families
for simplification. For wrought alloys a four-digit system is used to produce a list of
wrought composition families as follows:

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• 1xxx: Controlled unalloyed (pure) composition, used primarily in the electrical and
chemical industries
• 2xxx: Alloys in which copper is the principal alloying element, although other
elements, notably magnesium, may be specified.
2xxx series alloys are widely used in aircraft where their high strength (yield
strengths as high as 455 MPa, or 66 ksi) is valued.
• 3xxx: Alloys in which manganese is the principal alloying element, used as general-
purpose alloys for architectural applications and various products
• 4xxx: Alloys in which silicon is the principal alloying element, used in welding rods
and brazing sheet
• 5xxx: Alloys in which magnesium is the principal alloying element, used in boat
hulls, gangplanks, and other products exposed to marine environments
• 6xxx: Alloys in which magnesium and silicon are the principal alloying elements,
commonly used for architectural extrusions and automotive components
• 7xxx: Alloys in which zinc is the principal alloying element (although other
elements, such as copper, magnesium, chromium, and zirconium, may be specified),
used in aircraft structural components and other high-strength applications.

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CHAPTER-4
PREPARATION
CHAPTER-4
PREPARATION

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First of all, an exhaust hood fan requires the installation of an exhaust hood
duct. The duct allows the screened air to exit the interior of a home. Although there
are exhaust hoods that do not require a duct, these products do not really work well.
Determine whether the duct will exit to the outside of a wall or through the roof.
Check out instructions on installing the duct through a wall or through the roof for
more details.
4.1 Trace the Location for the Device
Take the exhaust hood fan and position it against the wall above the stove to
check how it fits. If it fits flush against the surface of the wall or under a pre-installed
cabinet, then trace that spot for future guidance. There are pre-drilled holes on the
hood that need to be screwed to the wall. Make sure to mark these holes on the wall
4.2 Secure the Device onto the Wall
Drill holes on the marked spots on the wall first then fit the device onto the
wall surface. Add a screw to every pre-drilled hole and tighten each one of them.
4.3 Connect the Wiring
Open the electrical cover on the device to reveal the fan motor, the light
switch and the fan switch. This will require the use of screwdrivers and a nut driver.
Open the electrical knockout as well with a screwdriver to expose the wires. Connect
the white wire on the hood fan to the white wire on the wall. Do the same with the
black wires. Afterwards, hook the bare wire on the wall to the ground screw on the
fan. Follow the same wiring connection for the light. Reinstall the cover.
4.4 Ventilation system
Ventilation fans are used to circulate the air in the buildings or houses. This
type of ventilation is known as mechanical ventilation in which fans or blowers are
used to create movement of the air. The other way to ventilate a house is using the
natural ventilation where the air is moved by natural forces.
A good design of a house will incorporate the natural ventilation as much as
possible to reduce the electricity bill as well as the conservation of the environment.

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However, it is inevitable that suitable fans will have to be installed to ensure that
the air quality in the house is fresh and safe for the people to stay.
4.5 Ventilation Fans - Volume of Air Change
The amount of air that needs to be ventilated is determined by the size of the
space measured using the air volume. Different space will need different ventilation
system. For instance, it is recommended that the kitchen should have an air change of
12 per hour.
If the volume of the kitchen is 5,000 cu feet, a fan with a capacity of
5,000X12=60,000 cu foot/hour(which is equivalent to 1,000 cfm) is required to have
an air change of 12 per hour. Cfm is cubic foot per minute and is usually specified in
the specifications of the fan.
4.6 TYPES OF VENTILATION SYSTEM
Exhaust Ventilation Systems:
Exhaust ventilation systems work by depressurizing the building. By reducing
the inside air pressure below the outdoor air pressure, they extract indoor air from a
house while make-up air infiltrates through leaks in the building shell and through
intentional, passive vents.
FIG 4.1 Exhaust ventilation systems
Exhaust ventilation systems are most applicable in cold climates. In climates
with warm, humid summers, depressurization can draw moist air into building wall
cavities, where it may condense and cause moisture damage.

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Exhaust ventilation systems are relatively simple and inexpensive to install.
Typically, an exhaust ventilation system is composed of a single fan connected to a
centrally located, single exhaust point in the house.
A preferable option is to connect the fan to ducts from several rooms
(especially rooms where pollutants tend to be generated, such as bathrooms).
Adjustable, passive vents through windows or walls can be installed to introduce
fresh air rather than rely on leaks in the building envelope. However, passive vents
may be ineffective because larger pressure differences than those induced by the
ventilation fan may be needed for them to work properly.
Spot ventilation exhaust fans installed in the bathroom but operated
continuously represent an exhaust ventilation system in its simplest form.One
concern with exhaust ventilation systems is that they may draw pollutants, along with
fresh air, into the house. For example, in addition to drawing in fresh outdoor air,
they may draw in the following:
 Radon and molds from a crawlspace
 Dust from an attic
 Fumes from an attached garage
 Flue gases from a fireplace or fossil fuel–fired water heater and furnace.
This can especially be of concern when bath fans, range fans, and clothes dryers
(which also depressurize the home while they operate) are run when an exhaust
ventilation system is also operating.
Exhaust ventilation systems can also contribute to higher heating and cooling
costs compared with energy recovery ventilation systems because exhaust systems do
not temper or remove moisture from the make-up air before it enters the house.
Supply Ventilation Systems:

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Supply ventilation systems work by pressurizing the building. They use a fan to force
outside air into the building while air leaks out of the building through holes in the
shell, bath- and range-fan ducts, and intentional vents.
FIG 4.2 Supply ventilation system
As with exhaust ventilation systems, supply ventilation systems are relatively
simple and inexpensive to install. A typical system has a fan and duct system that
introduces fresh air into usually one—but preferably several—rooms that residents
occupy most (for example, bedrooms, living room, kitchen). This system may
include adjustable window or wall vents in other rooms.
Supply ventilation systems allow better control of the air that enters the house
than do exhaust ventilation systems. By pressurizing the house, these systems
discourage the entry of pollutants from outside and prevent back drafting of
combustion gases from fireplaces and appliances. They also allow air introduced into
the house to be filtered to remove pollen and dust or to be dehumidified.
Supply ventilation systems work best in hot or mixed climates. Because they
pressurize the house, they have the potential to cause moisture problems in cold
climates.
In winter, the supply ventilation system causes warm interior air to leak
through random openings in the exterior wall and ceiling. If the interior air is humid
enough, some moisture may condense in the attic or parts of the exterior wall, where
it can promote mold, mildew, and decay.

25
Like exhaust ventilation systems, supply ventilation systems do not temper or
remove moisture from the air before it enters the house. Thus, they may contribute
to higher heating and cooling costs compared with energy recovery ventilation
systems. Because air is introduced in the house at discrete locations, outdoor air may
need to be mixed with indoor air before delivery to avoid cold air drafts in winter.
An in-line duct heater is another option, but it will increase operating costs.
Balanced Ventilation Systems:
Balanced ventilation systems, if properly designed and installed, neither
pressurizes nor depressurize a house. Rather, they introduce and exhaust
approximately equal quantities of fresh outside air and polluted inside air,
respectively. A balanced ventilation system usually has two fans and two duct
systems. It facilitates good distribution of fresh air by placing supply and exhaust
vents in appropriate places.
FIG 4.3 Balanced ventilation system
A typical balanced ventilation system is designed to supply fresh air to
bedrooms and common rooms where people spend the most time. It also exhausts air
from rooms where moisture and pollutants are most often generated, such as the
kitchen, bathrooms, and the laundry room.
Energy Recovery Systems:

26
Energy recovery ventilation systems usually cost more to install than other
ventilation systems. In general, simplicity is key to a cost-effective installation. To
save on installation costs, many systems share existing ductwork.
Complex systems are not only more expensive to install, but often they are also
more maintenance intensive and consume more electric power. For most houses,
attempting to recover all of the energy in the exhaust air will probably not be worth
the additional cost. Also, these types of ventilation systems are still not very
common. Only some HVAC contractors have enough technical expertise and
experience to install them.
In general, you want to have a supply and return duct for each bedroom and
for each common living area. Duct runs should be as short and straight as possible.
The correct size duct is necessary to minimize pressure drops in the system and thus
improve performance. Insulate ducts located in unheated spaces, and seal all joints
with duct mastic. Also, energy recovery ventilation systems operated in cold
climates must have devices to help prevent freezing and frost formation. Very cold
supply air can cause frost formation in the heat exchanger, which can damage it.
Frost build up also reduces ventilation effectiveness. In addition, energy recovery
ventilation systems need to be cleaned regularly to prevent deterioration of
ventilation rates and heat recovery, and to prevent mold and bacteria from forming
on heat exchanger surfaces.
4.7 INJECTION MOLDING FOR THE COMPONENT
Injection molding is a manufacturing technique for making parts from
both thermoplastic and thermosetting plastic materials in production. Molten
plastic is injected at high pressure into a mold, which is the inverse of the
product's shape. After a product is designed, usually by an industrial designer or
an engineer, molds are made by a mold maker (or toolmaker) from metal, usually
either steel or aluminum, and precision- machined to form the features of the desired
part. Injection molding is widely used for manufacturing a variety of parts, from the
smallest component to entire body panels of cars. Injection molding is the most
common method of production, with some commonly made items including bottle

27
caps and outdoor furniture. Injection molding typically is capable of tolerances
equivalent to an IT Grade of about 9–14.
The most commonly used thermoplastic materials are polystyrene (low cost,
lacking the strength and longevity of other materials), ABS or acrylonitrile
butadiene styrene (a teri- polymer or mixture of compounds used for everything
from Lego parts to electronics housings), polyamide (chemically resistant, heat
resistant, tough and flexible – used for combs), polypropylene (tough and
flexible – used for containers), polyethylene, and polyvinyl chloride or PVC (more
common in extrusions as used for pipes, window frames, or as the insulation on
wiring where it is rendered flexible by the inclusion of a high proportion of
plasticizer).
Injection molding can also be used to manufacture parts from
aluminum or brass (die casting). The melting points of these metals are much
higher than those of plastics; this makes for substantially shorter mold lifetimes
despite the use of specialized steels. Nonetheless, the costs compare quite favorably
to sand casting, particularly for smaller parts.
4.8 HISTORY
In 1868 John Wesley Hyatt became the first to inject hot celluloid into a
mold, producing billiard balls. He and his brother Isaiah patented an injection
molding machine that used a plunger in 1872, and the process remained more or
less the same until 1946, when James Hendry built the first screw injection
molding machine, revolutionizing the plastics industry. Roughly 95% of all
molding machines now use screws to efficiently heat, mix, and inject plastic into
molds.
4.8.1 EQUIPMENT
Injection molding machines, also known as presses, hold the molds in which
the components are shaped. Presses are rated by tonnage, which expresses the
amount of clamping force that the machine can generate. This pressure keeps the
mold closed during the injection process. Tonnage can vary from less than 5 tons
to 6000 tons, with the higher FIGs used in comparatively few manufacturing
operations.

28
Mold (Tool and/or Mold): is the common term used to describe the
production tooling used to produce plastic parts in molding.
Traditionally, molds have been expensive to manufacture. They were usually
only used in mass production where thousands of parts were being produced. Molds
are typically constructed from hardened steel, pre-hardened steel, aluminum,
and/or beryllium-copper alloy. The choice of material to build a mold is primarily
one of economics. Steel molds generally cost more to construct, but their longer
lifespan will offset the higher initial cost over a higher number of parts made
before wearing out. Pre-hardened steel molds are less wear resistant and are used
for lower volume requirements or larger components. The steel hardness is typically
38-45 on the Rockwell-C scale. Hardened steel molds are heat treated after
machining. These are by far the superior in terms of wear resistance and
lifespan. Typical hardness ranges between 50 and 60 Rockwell-C (HRC).
DESIGN
Molds separate into two sides at a parting line, the A side, and the B side, to
permit the part to be extracted. Plastic resin enters the mold through a sprue in
the A plate, branches out between the two sides through channels called runners,
and enters each part cavity through one or more specialized gates. Inside each
cavity, the resin flows around protrusions (called cores) and conforms to the cavity
geometry to form the desired part. The amount of resin required to fill the sprue,
runner and cavities of a mold is a shot. When a core shuts off against an opposing
mold cavity or core, a hole results in the part. Air in the cavities when the mold
closes escapes through very slight gaps between the plates and pins, into shallow
plenums called vents.
More complex parts are formed using more complex molds. These may have
sections called slides that move into a cavity perpendicular to the draw direction, to
form overhanging part features. Slides are then withdrawn to allow the part to be
released when the mold opens. Slides are typically guided and retained between rails
called gibs, and are moved when the mold opens and closes by angled rods called
horn pins and locked in place by locking blocks, both of which move cross the mold
from the opposite side.
The core and cavity, along with injection and cooling hoses form the mold
tool. While large tools are very heavy weighing hundreds and sometimes thousands

29
of pounds, they usually require the use of a forklift or overhead crane, they can be
hoisted into molding machines for production and removed when molding is
complete or the tool needs repairing.
4.8.2 MACHINING
Molds are built through two main methods: standard machining and
EDM machining. Standard Machining in its conventional form, has historically
been the method of building injection molds. With technological development,
CNC machining became the predominant means of making more complex molds
with more accurate mold details in less time than traditional method. The electrical
discharge machining (EDM) or spark erosion process has become widely used in
mold making. As well as allowing the formation of shapes which are difficult to
machine, the process allows pre-hardened molds to be shaped so that no heat
treatment is required. Changes to a hardened mold by conventional drilling and
milling normally require annealing to soften the steel, followed by heat treatment to
harden it again. EDM is a simple process in which a shaped electrode, usually made
of copper or graphite, is very slowly lowered onto the mold surface (over a period of
many hours), which is immersed in paraffin oil.
MOLDING TRAIL
When filling a new or unfamiliar mold for the first time, where shot size for
that mold is unknown, a technician/tool setter usually starts with a small shot
weight and fills gradually until the mold is 95 to 99% full. Once this is achieved a
small amount of holding pressure will be applied and holding time increased until
gate freeze off has occurred, then holding pressure is increased until the parts are
free of sinks and part weight has been achieved. Once the parts are good enough and
have passed any specific criteria, a setting sheet is produced for people to follow in
the future.
4.8.3 COLD-RUNNER MOLD
Cold-runner mold Developed to provide for injection of thermoset material
either directly into the cavity or through a small sub-runner and gate into the cavity.
It may be compared to the hot-runner molds with the exception that the manifold

30
section is cooled rather than heated to maintain softened but uncured material. The
cavity and core plates are electrically heated to normal molding temperature and
insulated from the cooler manifold section.
Types of Cold Runner Molds:
There are two major types of cold runner molds: two plate and three plate.
Two plate mold:
A two plate cold runner mold is the simplest type of mold. It is called a
two plate mold because there is one parting plane, and the mold splits into two
halves. The runner system must be located on this parting plane; thus the part can
only be gated on its perimeter.
Three plate mold:
A three plate mold differs from a two plate in that it has two parting
planes, and the mold splits into three sections every time the part is ejected. Since
the mold has two parting planes, the runner system can be located on one, the part on
the other. Three plate molds are used.
4.8.4 ADVANTAGES:
 The mold design is very simple, and much cheaper than a hot runner
 The mold requires less maintenance and less skill to set up and operate.
 The obvious disadvantage of this system is the waste plastic generated.
4.8.5 DISADVANTAGES
 The runners are either disposed of, or reground and reprocessed with the
original material.
 This adds a step in the manufacturing process. Also, regrind will increase
variation in the injection molding process, and could decrease the plastic's
mechanical properties.

31
4.8.6 HOT-RUNNER MOLD
Hot-runner mold - injection mold in which the runners are kept hot and
insulated from the chilled cavities. Plastic freeze off occurs at gate of cavity;
runners are in a separate plate so they are not, as is the case usually, ejected with the
piece.
Hot runner molds are two plate molds with a heated runner system inside
one half of the mold. A hot runner system is divided into two parts: the manifold
and the drops. The manifold has channels that convey the plastic on a single plane,
parallel to the parting line, to a point above the cavity. The drops, situated
perpendicular to the manifold, convey the plastic from the manifold to the part.
4.8.7 TYPES OF HOT-RUNNER MOLDS
There are many variations of hot runner systems. Generally, hot runner
systems are designated by how the plastic is heated. There are internally and
externally heated drops and manifolds.
Externally heated hot runners
Internally heated hot runners
4.8.8 ADVANTAGES OF HOT-RUNNER SYSTEM
 No runners to disconnect from the molded parts
 No runners to remove or regrind, thus no need for process/ robotics to
remove them having no runners reduces the possibility of contamination
 Lower injection pressures
 lower clamping pressure
 Consistent heat at processing temperature within the cavity
 Cooling time is actually shorter (as there is no need for thicker, longer-cycle
runners)
 Shot size is reduced by runner weight
 Cleaner molding process (no regrinding necessary)
 Nozzle freeze and sprue sticking issues eliminated.

32
4.8.9 DISADVANTAGES OF HOT-RUNNER MOLD
 Hot-runner mold is much more expensive than a cold runner, it requires
costly maintenance, and requires more skill to operate.
 Color changes with hot runner molds can be difficult, since it is virtually
impossible to remove all of the plastic from an internal runner system.

33
CHAPTER-5
INTRODUCTION TO CAD

34
CHAPTER-5
INTRODUCTION TO CAD
Computer Aided Design (CAD) is a technique in which man and machine are
blended in to problem solving team, intimately coupling the best characteristics of each.
The result of this combination works better than either man or machine would work
alone , and by using a multi discipline approach, it offers the advantages of
integrated team work.
The advances in Computer Science and Technology resulted in the emergence of
very powerful hardware and software tool. It offers scope for use in the entire design
process resulting in improvement in the quality of design. The emergency of CAD as a
field of specialization will help the engineer to acquire the knowledge and skills needed
in the use of these tools in an efficient and effective way on the design process.
Computer Aided Design is an interactive process, where the exchange of
information between the designer and the computer is made as simple and effective as
possible. Computer aided design encompasses a wide variety of computer based
methodologies and tools for a spectrum of engineering activities planning, analysis,
detailing, drafting, construction, manufacturing, monitoring, management, process
control and maintenance. CAD is more concerned with the use of computer-based tools
to support the entire life cycle of engineering system.
There are several good reasons for using a CAD system to support the engineering design
function:
 To increase the productivity
 To improve the quality of the design
 To uniform design standards
 To create a manufacturing data base
 To eliminate inaccuracies caused by hand-copying of drawings and inconsistency
 Drawings

35
5.1 CAD/CAM HISTORY
The concept of CAD and CAM is relatively new. The usage is linked with the
development of computers. The actual application of CAD/CAM in industry, academia
and government is only approximately 30 years old. Formal courses in CAD and Finite
Element Analysis (FEA) were introduced in 1970’s. The major application thrust of CAD
came in 1980’s, with the availability of PCs and workstations. In its early stage of usage,
very few engineering companies could afford the expense of mainframe computers;
however, PCs and workstations have evolved into affordable and adequate platform to
support comprehensive CAD packages that initially were designed to run on the
mainframe platform.
A brief history of the evolution of CAD/CAM, according to the decade and the
major CAD/CAM developments.
5.2 INTRODUCTION TO CATIA
CATIA also known as Computer Aided Three-dimensional Interactive
Application and it is software suit that developed by the French company call Dassult
Systems.
CATIA is a process-centric computer-aided design/computer-assisted
manufacturing/computer-aided engineering (CAD/CAM/CAE) system that fully uses
next generation object technologies and leading edge industry standards. CATIA is
integrated with Dassult Systems Product Lifecycle Management (PLM) solutions. It
allows the users to simulate their industrial design processes from initial concept to
product design, analysis, assembly and also maintenance. In this software, it includes
mechanical, and shape design, styling, product synthesis, equipment and systems
engineering, NC manufacturing, analysis and simulation, and industrial plant design. It is
very user friendly software because CATIA Knowledge ware allows broad communities
of user to easily capture and share know-how, rules, and other intellectual property assets.

36
5.2.1 ENGINEERING DESIGN
Catia V5 offers a range of tools to enable the generation of a complete digital
representation of the product being designed. In addition to the general geometry tools
there is also the ability to generate geometry of other integrated design disciplines such as
industrial and standard pipe work and complete wiring definitions. Tools are also
available to support collaborative development.
A number of concept design tools that provide up-front Industrial Design concepts can
then be used in the downstream process of engineering the product. These range from
conceptual Industrial design sketches, reverse engineering with point cloud data and
comprehensive freeform surface tools.
5.2.2 Different Modules in Catia V5
 Sketcher
 Part Modeling
 Surfacing
 Sheet Metal
 Drafting
 Manufacturing
 Shape designs
 Wireframe and surface design

37
FIG 5.1 Design of injection mould tool design
FIG 5.2 DESIGN OF EXHUAST FAN MODEL

38
CHAPTER-6
ANSYS OF EXHAUST FAN

39
CHAPTER-6
ANSYS OF EXHAUST FAN
6.1 INTRODUCTION TO CAE:
Computer-aided engineering (CAE) is the broad usage of computer software to
aid in engineering analysis tasks. It includes Finite Element Analysis (FEA),
Computational Fluid Dynamics (CFD), Multi body dynamics (MBD), and optimization.
Software tools that have been developed to support these activities are considered
CAE tools. CAE tools are being used, for example, to analyze the robustness and
performance of components and assemblies. The term encompasses
simulation, validation, and optimization of products and manufacturing tools. In the
future, CAE systems will be major providers of information to help support design teams
in decision making.
In regard to information networks, CAE systems are individually considered a
single node on a total information network and each node may interact with other nodes
on the network.
CAE systems can provide support to businesses. This is achieved by the use of
reference architectures and their ability to place information views on the business
process. Reference architecture is the basis from which information model, especially
product and manufacturing models.
The term CAE has also been used by some in the past to describe the use of
computer technology within engineering in a broader sense than just engineering
analysis. It was in this context that the term was coined by Jason Lemon, founder
of SDRC in the late 1970s. This definition is however better known today by the
terms CAX and PLM

40
Stress analysis on components and assemblies using FEA (Finite Element Analysis);
 Thermal and fluid flow analysis Computational fluid dynamics (CFD);
 Multi body dynamics (MBD) & Kinematics;
 Analysis tools for process simulation for operations such as casting, molding,
and die press forming.
 Optimization of the product or process.
 Safety analysis of postulate loss-of-coolant accident in nuclear reactor using
realistic thermal-hydraulics code.
In general, there are three phases in any computer-aided engineering task:
 Pre-processing – defining the model and environmental factors to be applied
to it. (typically a finite element model, but facet, voxel and thin sheet method)
 Analysis solver (usually performed on high powered computers)
 Post-processing of results (using visualization tools)
CAE IN AUTOMATIVE INDUSTRY
CAE tools are very widely used in the automotive industry. In fact, their use has
enabled the automakers to reduce product development cost and time while improving
the safety, comfort, and durability of the vehicles they produce. The predictive capability
of CAE tools has progressed to the point where much of the design verification is now
done using computer simulations rather than physical prototype testing. CAE
dependability is based upon all proper assumptions as inputs and must identify critical
inputs (BJ). Even though there have been many advances in CAE, and it is widely used in
the engineering field, physical testing is still used as a final confirmation for subsystems
due to the fact that CAE cannot predict all variables in complex assemblies (i.e. metal
stretch, thinning).
6.2 FINITE ELEMENT ANALYSIS (FEA)
The Basic concept in FEA is that the body or structure may be divided into

41
smaller elements of finite dimensions called “Finite Elements”. The original body or the
structure is then considered as an assemblage of these elements connected at a finite
number of joints called “Nodes” or “Nodal Points”. Simple functions are chosen to
approximate the displacements over each finite element. Such assumed functions are
called “shape functions”. This will represent the displacement within the element in terms
of the displacement at the nodes of the element.
The Finite Element Method is a mathematical tool for solving ordinary and partial
differential equations. Because it is a numerical tool, it has the ability to solve the
complex problems that can be represented in differential equations form. The applications
of FEM are limitless as regards the solution of practical design problems.
Due to high cost of computing power of years gone by, FEA has a history of
being used to solve complex and cost critical problems. Classical methods alone usually
cannot provide adequate information to determine the safe working limits of a major civil
engineering construction or an automobile or an aircraft. In the recent years, FEA has
been universally used to solve structural engineering problems. The departments, which
are heavily relied on this technology, are the automotive and aerospace industry. Due to
the need to meet the extreme demands for faster, stronger, efficient and lightweight
automobiles and aircraft, manufacturers have to rely on this technique to stay
competitive.
FEA has been used routinely in high volume production and manufacturing
industries for many years, as to get a product design wrong would be detrimental. For
example, if a large manufacturer had to recall one model alone due to a hand brake
design fault, they would end up having to replace up to few millions of hand brakes. This
will cause a heavier loss to the company.
The finite element method is a very important tool for those involved in
engineering design;
It is now used routinely to solve problems in the following areas.
 Structural analysis
 Thermal analysis
 Fluid flow simulations
 Crash simulations

42
 Mold flow simulations, etc.
Nowadays, even the most simple of products rely on the finite element method for design
evaluation. This is because contemporary design problems usually cannot be solved as
accurately & cheaply using any other method that is currently available. Physical testing
was the norm in the years gone by, but now it is simply too expensive and time
consuming also.
6.3 INTRODUCTION TO ANSYS
ANSYS is general-purpose finite element analysis (FEA) software package.
Finite Element Analysis is a numerical method of deconstructing a complex system into
very small pieces (of user-designated size) called elements. The software implements
equations that govern the behaviour of these elements and solves them all; creating a
comprehensive explanation of how the system acts as a whole. These results then can be
presented in tabulated or graphical forms. This type of analysis is typically used for the
design and optimization of a system far too complex to analyze by hand. Systems that
may fit into this category are too complex due to their geometry, scale, or governing
equations.
ANSYS is the standard FEA teaching tool within the Mechanical Engineering
Department at many colleges. ANSYS is also used in Civil and Electrical Engineering, as
well as the Physics and Chemistry departments.
ANSYS provides a cost-effective way to explore the performance of products or
processes in a virtual environment. This type of product development is termed virtual
prototyping.
With virtual prototyping techniques, users can iterate various scenarios to
optimize the product long before the manufacturing is started. This enables a reduction in
the level of risk, and in the cost of ineffective designs. The multifaceted nature of
ANSYS also provides a means to ensure that users are able to see the effect of a design
on the whole behavior of the product, be it electromagnetic, thermal, mechanical etc.

43
6.4 STEPS INVOLVED IN ANSYS
In general, a finite element solution can be broken into the following these categories.
1. PREPROCESSING MODEL Defining the problem
The major steps in preprocessing are given below
 Defining key points /lines/areas/volumes
 Define element type and material /geometric /properties
 Mesh lines/areas/volumes/are required
The amount of detail required will depend on the dimensionality of the analysis
(i.e. 1D, 2D, axis, symmetric)
2. SOLUTION PROCESSOR MODULE Assigning the loads ,constraints and solving.
Here we specify the loads (point or pressure), constraints (translation, rotational) and
finally solve the resulting set of equations.
3. POST PROCESSING MODULE Further processing and viewing of results
In this stage we can see:
 List of nodal displacement
 Elements forces and moments
 Deflection plots
 Stress contour diagrams
6.5 CFD OVERVIEW
Computational fluid dynamics (CFD) is the numerical analysis of fluid flow, heat
transfer, and related phenomena. CFD solvers contain a complex set of algorithms used
for modeling and simulating the flow of fluids, gases, heat, and electric currents. Many
technological advances in aeronautics, automobiles, and space would not be possible
without CFD. Applications such as aerofoil design in aeronautics, drag simulation in

44
automobile design, jet and thermal flow in engine design, and cooling airflow in an
electronic product use the CDF methodology.
CFD enables you to predict fluid flow, heat and mass transfer, and chemical
reactions (explosions) and related phenomena. It is used in almost all industrial sectors:
food processing, water treatment, marine engineering, automotive, aerodynamics, and gas
turbine design. With the help of CFD software, fluid flow problems are analyzed faster
than by testing, in more detail, at an earlier stage in the design cycle, for less money, and
with lower risk.
6.6 CFD ANALYSIS OF EXHAUST FAN
Import as .iges format.
Ansys → Workbench→ Select analysis system → Fluid Flow (Fluent) → double click
→Select geometry → right click → import geometry → select browse →open part → ok
→ select mesh on work bench → right click →edit
Material properties of ABS Plastic
Density = 1530 kg/m3
Specific heat = 1200 j/kg-k
Thermal conductivity = 0.1w/m-k
melting temperature= 550K

46
FIG 6.2 MESHING MODEL
Select mesh on left side part tree → right click → generate mesh →
FIG 6.3 MATERIAL INPUTS
Select models →select energy →edit→ on

47
FIG 6.4 MODEL
OF ANSYS
Select material → properties → add
required material properties→ ok
FIG 6.5 BOUNDARY CONDITIONS
File→export→ fluent →input file(mesh) →enter required name →save.
→ansys →fluid dynamics → fluent →select 2D or 3D →select working directory →ok
→file →read →mesh →select file →ok

48
FIG 6.6 ITERATIONS
CHAPTER-7
RESULT

49
RESULTS
After giving the proper boundary conditions solid works flow simulation run the
analysis in cut plots we can check the results. Flow simulation is done with aluminum
and ABS Plastic material. the results for different pressure inlet taken for Exhaust fan
MATERIAL-ALUMINIUM

50
FIG 7.1 PRESSURE CUT PLOT TO ALUMINIUM
FIG 7.2 VELOCITY TO ALUMINIUM

51
FIG 7.3 TEMPERAURE OF FLUID TO ALUMINIUM
FIG 7.4 HEAT TRANSFER CO-EFFICIENT TO ALUMINIUM

52
MASS FLOW RATE
Mass Flow Rate (kg/s)
-------------------------------- --------------------
inlet 1951.7234
interior-partbody 37.282341
outlet -1947.822
wall-partbody 0
---------------- --------------------
Net 3.9013672
TOTAL HEAT TRANSFER RATE
Total Heat Transfer Rate (w)
-------------------------------- --------------------
inlet 1.051424e+08
outlet -1.0497328e+08
wall-partbody 0
---------------- --------------------
Net 16.9120

53
MATERIAL-ABS PLASTIC
FIG 7.5 PRESSURE CUT PLOT TO ABS PLASTIC
FIG 7.6 VELOCITY TO ABS PLASTIC

54
FIG 7.7 TEMPERAURE OF FLUID TO ABS PLASTIC
FIG 7.8 HEAT TRANSFER CO-EFFICIENT TO ABS PLASTIC

55
MASS FLOW RATE
Mass Flow Rate (kg/s)
----------------------------------------------------
Inlet 1560.0181
Interior-part body 36.241684
Outlet -1559.9971
Wall-partbody 0
---------------- --------------------
Net 0.020996094
TOTAL HEAT TRANSFER RATE
Total Heat Transfer Rate (w)
----------------------------------------------------
Inlet 1800883.3
Outlet -1800858.8
Wall-part body 0
---------------- --------------------
Net 24.5

56
Result table
Aluminum ABS plastic
Pressure(MPa) 1.59e+08 1.67e+08
velocity(m/s) 1.61e+04 1.75e+04
Temperature(K) 3.60e+02 3.00e+02
Heat transfer co-
efficient(w/mk)
1.78e+05 6.22e+04
Mass flow rate(kg/s) 3.9013672 0.020996094
Total heat transfer rate(w) 16.9120 24.5

58
CHAPTER-8
CONCLUSION
Presently exhaust fans are made with metals. So fan weight is more and
consequently high power is required for the fan rotation. The main aim of this project is
to develop a mould for the exhaust fan using ABS Plastic material.
The parametric modeling of exhaust fan is done in CATIA V5 R20. Fluid flow
analysis is done using Plastic Advisor module in ANSYS. The input parameters to check
the mould flow are Maximum Injection Pressure –180MPa, Mold temperature –60deg C
and Melt Temperature –230deg C.
By checking the analysis results, Heat transfer co-efficient is more for ABS
plastic compare to aluminum.

59
REFERENCES
1. Coroneos R M 2012 Structural Analysis and Optimization of a Composite Fan
Blade for Future Aircraft Engine NASA/TM—2012-217632
2. Fenner P E and Watson A 2012 Finite element buckling analysis of stiffened
plates with filleted junctions Thin-Walled Structures59pp 171-18
3. Heidari M A, Carlson D L and Yantis T 2002 Rotor-dynamics Analysis Process
Worldwide Aerospace Conference & Technology Showcase - Toulouse2002 36pp
4. Gafiţanu M, Creţu Sp and Drăgan B 1989 Vibro-acoustic diagnosis of
machinery(Bucureşti: Editura Tehnică)
5. Radeş M 2008 Mechanical Vibrations(Editura Printech) .
6. R. G. Desavale, A. M. Patil, “Theoretical and Experimental Analysis of Torsional
and Bending Effect on Four Cylinders Engine Crankshafts by Using Finite
Element Approach,” International Journal of sudheeraarunEngineering Research,
2013, 2, 379-385.
7. G. Rui, Jang, Choi, “Torsional vibration analysis of lathe spindle system with
unbalanced workpiece,” J. Cent. South Univ. Technol., 2011, 18, 171-176.
8. K. A. Gul, Thesis: Modeling and Analysis of Engine Cold-TestCells for
Optimizing Driveline Design for Structural Reliability and Engine Assembly
Defect Diagnostics, 2013.
9. G. Genta, “Vibration dynamic and control,”Springer, 2009, pp.764-766.
10. A. Boysal, H. Rahnejat, “Torsional vibration analysis of multi-body single
cylinder internal combustion engine model,” Appl.Math. Modelling, 1997, 21,
481-493.

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