it is an acadamic project about how to create complex geometry for heatsink. In this project i designed a heatsink by implementing thermal topology optimization technique using altair's hyperworks Optistruct solver and manufactured it using additive manufacturing to obtain complex geometry for convective heat transfer.
This document describes the design, fabrication, and analysis of an automobile radiator test rig using MATLAB. The main divisions of the project include estimating costs, designing the cooling system in MATLAB, assembling components to create the test rig, and analyzing rig values for different parameters. The test rig components include a reservoir, pump, rotameter, thermocouples, radiator, fan, and coolant bottle. Experiments are conducted using water and coolant at different dilution levels. Observations of inlet/outlet temperatures and efficiency calculations are made. Results show inlet temperature decreases with increasing outlet temperature. Thermal efficiency increases with greater temperature difference. The project concludes with recommendations for further analysis and simulation of the system.
The document discusses different methods of cooling turbine blades in gas turbine engines. It describes how turbine blade cooling aims to reduce thermal stresses and temperatures to improve service life and efficiency. The main methods discussed are internal cooling using air passed through internal passages in the blades, and external cooling using film cooling, transpiration cooling or liquid cooling. Internal cooling techniques include convection and impingement, while external cooling uses holes or pores to eject cooling air and form a protective film over the hot blade surfaces. Liquid cooling provides higher heat transfer but requires complex systems to circulate the liquid. Blade cooling allows higher inlet temperatures to turbines, improving efficiency.
CFD Analysis of Heat Transfer Enhancement in Shell and Tube Type Heat Exchang...ijtsrd
Shell and Tube heat exchangers are having special importance in boilers, oil coolers, condensers, pre-heaters. Shell and Tube heat exchanger is one such heat exchanger, provides more area for heat transfer between two fluids in comparison with other type of heat exchanger. To intensify heat transfer with minimum pumping power innovative heat transfer fluids called Nano fluids have become the major area of research now a days. The primary aim is to evaluate the effect of different weight concentration and temperatures on convective heat transfer. Increasing the weight concentration and temperatures leads to enhancement of convective heat transfer coefficient. In the present, work attempts are made to enhance the heat transfer rate in shell and tube heat exchangers. A multi pass shell and tube heat exchanger with 3 tubes with fins modelling is done using ANSYS. Nanofluid such as Al2O3-H2O is used. The CFD simulated results achieved from the use of the creating fin in tube side in shell and tube type heat exchanger are compared with without fin. Based on the results, providing fins on tube causes the increment of overall heat transfer coefficient which results in the enhancement of heat transfer rate of heat exchanger. Sudhanshu Pathak | H. S. Sahu"CFD Analysis of Heat Transfer Enhancement in Shell and Tube Type Heat Exchanger creating Triangular Fin on the Tubes" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-2 | Issue-4 , June 2018, URL: http://www.ijtsrd.com/papers/ijtsrd14259.pdf http://www.ijtsrd.com/engineering/mechanical-engineering/14259/cfd-analysis-of-heat-transfer-enhancement-in-shell-and-tube-type-heat-exchanger-creating-triangular-fin-on-the-tubes/sudhanshu-pathak
1. Pool boiling occurs when a heated surface transfers heat to a liquid through natural convection and the formation of bubbles at the surface.
2. There are four regimes of pool boiling as excess temperature increases: natural convection, nucleate boiling, transition boiling, and film boiling. In nucleate boiling, bubbles form rapidly at nucleation sites on the surface.
3. The pool boiling curve graphs heat flux against the temperature excess of a surface above the liquid's boiling point. It shows regions of unstable and stable boiling across the different boiling regimes.
The cooling system uses five basic parts - water jackets, water pump, thermostat, radiator, and fan - to regulate the engine's temperature. The water pump circulates coolant through the water jackets in the engine and then into the radiator, where the coolant is cooled by the airflow of the fan before returning to the engine. The thermostat controls the flow of coolant to maintain optimal engine temperature. The cooling system is needed to prevent overheating and damage to engine parts from high temperatures during operation.
The document summarizes the working of a vapour absorption refrigeration system. It begins by explaining that this system uses heat energy instead of mechanical energy like a vapour compression system. It then describes the key components of a simple vapour absorption system - an absorber, pump, generator and pressure reducing valve which replace the compressor. It notes that in practical systems, an analyser and rectifier are added along with heat exchangers to improve performance and efficiency. Some advantages of absorption systems over compression systems are also listed, such as being quieter and able to use low-grade heat sources.
Aircraft refrigeration system (air cooling system)Ripuranjan Singh
Aircraft air refrigeration systems are required due to heat transfer from many external and internal heat sources (like solar radiation and avionics) which increase the cabin air temperature. With the technological developments in high-speed passenger and jet aircraft's, the air refrigeration systems are proving to be most efficient, compact and simple. Various types of aircraft air refrigeration systems used these days are.
Simple air cooling system
Simple air evaporative cooling system
Boot strap air cooling system
Boot strap air evaporative cooling system
Reduced ambient air cooling system
Regenerative air cooling system
COMPRESSOR EFFICIENCY AND TURBINE EFFICIENCY.
Comparison of Various Air Cooling Systems used for Aircraft ON basis of dart
The document discusses the bootstrap air cycle refrigeration system. It consists of a primary heat exchanger, secondary heat exchanger, and cooling turbine. Ram air is used to cool the heat exchangers. High pressure air is compressed, cooled in the primary heat exchanger, compressed further, and has more heat removed in the secondary heat exchanger before expanding through the turbine to provide cabin cooling. The bootstrap system uses two compressors to raise the air pressure in two stages for use on aircraft to provide cooling while in flight when ram air is available to aid heat removal.
This document describes the design, fabrication, and analysis of an automobile radiator test rig using MATLAB. The main divisions of the project include estimating costs, designing the cooling system in MATLAB, assembling components to create the test rig, and analyzing rig values for different parameters. The test rig components include a reservoir, pump, rotameter, thermocouples, radiator, fan, and coolant bottle. Experiments are conducted using water and coolant at different dilution levels. Observations of inlet/outlet temperatures and efficiency calculations are made. Results show inlet temperature decreases with increasing outlet temperature. Thermal efficiency increases with greater temperature difference. The project concludes with recommendations for further analysis and simulation of the system.
The document discusses different methods of cooling turbine blades in gas turbine engines. It describes how turbine blade cooling aims to reduce thermal stresses and temperatures to improve service life and efficiency. The main methods discussed are internal cooling using air passed through internal passages in the blades, and external cooling using film cooling, transpiration cooling or liquid cooling. Internal cooling techniques include convection and impingement, while external cooling uses holes or pores to eject cooling air and form a protective film over the hot blade surfaces. Liquid cooling provides higher heat transfer but requires complex systems to circulate the liquid. Blade cooling allows higher inlet temperatures to turbines, improving efficiency.
CFD Analysis of Heat Transfer Enhancement in Shell and Tube Type Heat Exchang...ijtsrd
Shell and Tube heat exchangers are having special importance in boilers, oil coolers, condensers, pre-heaters. Shell and Tube heat exchanger is one such heat exchanger, provides more area for heat transfer between two fluids in comparison with other type of heat exchanger. To intensify heat transfer with minimum pumping power innovative heat transfer fluids called Nano fluids have become the major area of research now a days. The primary aim is to evaluate the effect of different weight concentration and temperatures on convective heat transfer. Increasing the weight concentration and temperatures leads to enhancement of convective heat transfer coefficient. In the present, work attempts are made to enhance the heat transfer rate in shell and tube heat exchangers. A multi pass shell and tube heat exchanger with 3 tubes with fins modelling is done using ANSYS. Nanofluid such as Al2O3-H2O is used. The CFD simulated results achieved from the use of the creating fin in tube side in shell and tube type heat exchanger are compared with without fin. Based on the results, providing fins on tube causes the increment of overall heat transfer coefficient which results in the enhancement of heat transfer rate of heat exchanger. Sudhanshu Pathak | H. S. Sahu"CFD Analysis of Heat Transfer Enhancement in Shell and Tube Type Heat Exchanger creating Triangular Fin on the Tubes" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-2 | Issue-4 , June 2018, URL: http://www.ijtsrd.com/papers/ijtsrd14259.pdf http://www.ijtsrd.com/engineering/mechanical-engineering/14259/cfd-analysis-of-heat-transfer-enhancement-in-shell-and-tube-type-heat-exchanger-creating-triangular-fin-on-the-tubes/sudhanshu-pathak
1. Pool boiling occurs when a heated surface transfers heat to a liquid through natural convection and the formation of bubbles at the surface.
2. There are four regimes of pool boiling as excess temperature increases: natural convection, nucleate boiling, transition boiling, and film boiling. In nucleate boiling, bubbles form rapidly at nucleation sites on the surface.
3. The pool boiling curve graphs heat flux against the temperature excess of a surface above the liquid's boiling point. It shows regions of unstable and stable boiling across the different boiling regimes.
The cooling system uses five basic parts - water jackets, water pump, thermostat, radiator, and fan - to regulate the engine's temperature. The water pump circulates coolant through the water jackets in the engine and then into the radiator, where the coolant is cooled by the airflow of the fan before returning to the engine. The thermostat controls the flow of coolant to maintain optimal engine temperature. The cooling system is needed to prevent overheating and damage to engine parts from high temperatures during operation.
The document summarizes the working of a vapour absorption refrigeration system. It begins by explaining that this system uses heat energy instead of mechanical energy like a vapour compression system. It then describes the key components of a simple vapour absorption system - an absorber, pump, generator and pressure reducing valve which replace the compressor. It notes that in practical systems, an analyser and rectifier are added along with heat exchangers to improve performance and efficiency. Some advantages of absorption systems over compression systems are also listed, such as being quieter and able to use low-grade heat sources.
Aircraft refrigeration system (air cooling system)Ripuranjan Singh
Aircraft air refrigeration systems are required due to heat transfer from many external and internal heat sources (like solar radiation and avionics) which increase the cabin air temperature. With the technological developments in high-speed passenger and jet aircraft's, the air refrigeration systems are proving to be most efficient, compact and simple. Various types of aircraft air refrigeration systems used these days are.
Simple air cooling system
Simple air evaporative cooling system
Boot strap air cooling system
Boot strap air evaporative cooling system
Reduced ambient air cooling system
Regenerative air cooling system
COMPRESSOR EFFICIENCY AND TURBINE EFFICIENCY.
Comparison of Various Air Cooling Systems used for Aircraft ON basis of dart
The document discusses the bootstrap air cycle refrigeration system. It consists of a primary heat exchanger, secondary heat exchanger, and cooling turbine. Ram air is used to cool the heat exchangers. High pressure air is compressed, cooled in the primary heat exchanger, compressed further, and has more heat removed in the secondary heat exchanger before expanding through the turbine to provide cabin cooling. The bootstrap system uses two compressors to raise the air pressure in two stages for use on aircraft to provide cooling while in flight when ram air is available to aid heat removal.
The document presents information on a bootstrap air cooling system suitable for aircraft. It consists of two heat exchangers, a secondary compressor driven by a turbine, and uses ram air and compression to cool and circulate air. Ambient air is compressed by the main aircraft compressor then cooled in an air cooler before further compression and cooling. It is then expanded through a turbine to provide cooled air to the aircraft cabin. Advantages are that air is readily available, non-toxic, and pressures are low. A limitation is that it requires aircraft flight for ram air cooling and is not suitable for ground use without an additional fan.
1. Combustion involves the rapid chemical combination of fuel and oxygen, resulting in heat release. It requires a combustible mixture, an ignition source, and flame propagation.
2. In spark ignition (SI) engines, a carburetor supplies an air-fuel mixture and a spark plug ignites it. Combustion in SI engines occurs in three stages: ignition lag, flame propagation, and afterburning.
3. Factors like air-fuel ratio, compression ratio, load, turbulence, and engine speed affect the flame propagation rate in SI engines. Higher propagation speeds improve efficiency and fuel economy.
Refrigeration and air conditioning systems work by removing heat from an enclosed space to lower its temperature below the surrounding environment. There are two main types of refrigeration systems - vapor compression cycles and vapor absorption cycles. Vapor compression cycles use a compressor, condenser, expansion valve, and evaporator to remove heat. Vapor absorption cycles use heat to drive the refrigeration process rather than electricity. Air conditioning systems build on refrigeration principles to simultaneously control temperature, humidity, air motion, and quality within an enclosed space.
Choosing the right Rubber Calender is important; learning to operate it smartly is equally key for your success with this machine. This edition covers all these aspects in a descriptive manner.
The document discusses OptiStruct, a structural analysis solver from Altair Engineering. It can analyze and optimize structural designs for strength, durability, and noise and vibration performance. It uses finite element analysis and multi-body dynamics techniques. The document also outlines an agenda covering new features like auto-contact detection, pretension management tools, and domain decomposition parallelization. It provides examples of using these new features to simplify modeling and improve performance on large models.
Moulds For Tyre Industries,Rubber Machine Mould Manufacturerjeykaveda
Welcome to S.R. Engineering,We are Manufacturers & Exports of Conveyor Manufacturer,Material Handling Equipment ,Re-conditioning & Refurbishment,Rubber Processing Machine,Mould For Tyre
Psychrometry and Air conditioning load estimationNITIN AHER
This document discusses psychrometrics and air conditioning load estimation. It covers topics like:
- The composition of air and properties of moist air like humidity ratio, enthalpy, specific volume.
- Psychrometric chart which graphically represents thermodynamic properties of moist air.
- Basic psychrometric processes like sensible heating/cooling, humidification, dehumidification.
- Methods to achieve these processes like air washers, evaporative cooling, steam injection.
- Factors affecting human comfort and the use of comfort charts.
- Estimating cooling loads for air conditioning systems.
Walk in cooler & freezer cold room plant & refrigerated cold storage warehous...svfd1721
This document provides instructions for the design, installation, operation, and maintenance of walk-in coolers and freezers. It discusses product information and applications, installation procedures, operational instructions, control settings, and maintenance guidelines. The document contains diagrams of electrical wiring and refrigeration systems. Maintaining proper temperature settings, cleaning, and routine maintenance are emphasized for optimal performance of walk-in cold storage units.
Blend
Up to 30 ingredients are used in your tyre’s rubber blend. The ingredient proportions will depend on what the performance goals of the tyre will be. It’s composed of several types of rubber, fillers and other ingredients, mixed in giant blenders known as Banbury mixers. These create a black gummy compound that’ll be sent on for
milling.
The Process of Making a Tyre - Banner 2Mill
Once the rubber is cooled, it’s sent to a special mill where the rubber is cut into strips that will form the basic structure of your tyre. At the milling stage, other elements of the tyre are prepared, some of which are then coated in another type of rubber.
The Process of Making a Tyre - Banner 3Build
The tyre itself is constructed, from the inside out. The textile elements, steel belts, beads, ply, tread, and other components are placed in a tyre-building machine that ensures every part is in its precise location. This results in what looks like a relatively finished product, known as a green tyre.
The Process of Making a Tyre - Banner 4
Cure
The green tyre is then vulcanised with hot moulds in a curing press, compressing all of the parts of the tyre together and giving the tyre its final shape, including its tread pattern and manufacturer’s sidewall markings.
A Stirling engine operates by compressing and expanding a gas between a hot side and cold side of a cylinder. The engine was invented in 1816 by Robert Stirling. It works based on the temperature difference between the two sides of its cylinder. The gas inside is moved between the hot and cold sides, expanding on the hot side and contracting on the cold side. There are different configurations of Stirling engines, including alpha, beta, and gamma types. The ideal Stirling cycle consists of four thermodynamic processes: isothermal expansion, constant volume heat removal, isothermal compression, and constant volume heat addition. Stirling engines can be used in submarines, for cooling rooms, in aircraft, and in boats
The document discusses the components and operation of an anti-lock braking system (ABS). It describes the key components of ABS including speed sensors that monitor wheel rotation, valves that control hydraulic brake pressure, a pump to supply pressure, and a controller that monitors sensor data and actuates the valves. It explains that the controller detects wheels that are slowing too quickly, indicating a risk of lockup, and uses the valves to reduce brake pressure to that wheel to maintain traction. Modern ABS and stability control systems apply this principle across all four wheels using individual wheel sensors and controls.
This document provides information about hydraulic and pneumatic braking systems. It discusses the principles and components of hydraulic braking systems, including drum and disc types. It explains that hydraulic brakes use pressurized brake fluid to apply equal braking force to all wheels. Pneumatic braking systems are also covered, noting that they use compressed air as the working fluid. The key components of a pneumatic system are described along with how the air pressure is stored and distributed to brake chambers to slow the vehicle. Advantages of both hydraulic and pneumatic systems are presented.
1) Group analyzed crashworthiness of a 1500 pickup truck through FE simulations of frontal impacts at 30 mph and 35 mph and an oblique 30 mph side impact.
2) Key results included barrier forces, displacements, velocities and accelerations which showed increased impact at higher velocity. Pole impact introduced most stress due to concentration.
3) Analysis provided understanding of FMVSS 208, NCAP tests and how vehicle and components absorb crash energy. Recommendations to improve model and validation were provided.
Thermodynamic Design of a Fire-Tube Steam BoilerJohn Walter
This document summarizes the thermodynamic design of a fire-tube steam boiler. It includes an introduction describing the key components of a fire-tube boiler. The design analysis section shows calculations for temperature distribution, heat transfer within the boiler, area for the second and third passes, and volume ratios. The design outcome provides the dimensions and specifications determined for the boiler, including a boiler length of 5m, diameter of 2m, and furnace diameter of 0.8m. Supporting data is also included in an Excel file.
The cylinder head determines key engine properties like power output, torque, and emissions. Cylinder heads require materials with high mechanical properties above 150°C due to the complex shapes and high stresses during operation. For passenger cars, aluminum is commonly used due to its properties, while cast iron is used for larger engines. Modern cylinder heads, especially for direct injection diesel engines, require alloys with high tensile strength, creep resistance up to 250°C, thermal conductivity, and ductility to withstand thermal stresses. Common casting methods include sand casting, permanent mold casting, lost foam, and pressure die-casting, using cast iron or aluminum alloys.
This document provides information on various plastic joining processes including ultrasonic welding, vibration welding, spin welding, and induction welding. It discusses the principles, advantages, disadvantages, applications, suitable materials, and design recommendations for each process. The key points are:
1. Ultrasonic welding uses high-frequency vibrations to melt plastic surfaces and join them. It is fast and economical but requires specifically designed joints.
2. Vibration welding generates heat through high-amplitude, low-frequency vibrations. It can join large parts but has initial high equipment costs.
3. Spin welding friction welds circular joints by rotating one part at high speed. It is simple and energy efficient but limited to circular
The document discusses the analysis of brake drums using finite element modeling. It begins by stating that brake drums experience high thermal stresses from braking and need to withstand both thermal and mechanical loads. Finite element analysis is used to accurately model stress distribution since an analytical solution is not possible due to complex loading conditions. The analysis focuses on an internally expanding brake drum used in medium-duty vehicles.
Structural modeling and meshing of blast furnace using TCL/Tk scripting.debiprasadghosh
The document describes modeling and meshing of a blast furnace structure using HyperMesh and finite element analysis software. Key steps include:
1. Creating the blast furnace geometry in HyperMesh using solid modeling techniques.
2. Generating a mesh and applying material properties, boundary conditions, and loads representing the blast furnace's operation.
3. Exporting the model to ANSYS and using Tcl/Tk scripts to automate running iterative simulations with modified parameters.
4. Viewing stress results in HyperView to evaluate design changes and optimize the blast furnace structure.
Recent advances in semiconductor technology show the improvement of fabrication on
electronics appliances in terms of performance, power density and even the size. This great achievement
however led to some major problems on thermal and heat distribution of the electronic devices. This
thermal problem could reduce the efficiency and reliability of the electronic devices. In order to minimize
this thermal problem, an optimal cooling techniques need to be applied during the operation. There are
various cooling techniques have been used and one of them is passive pin fin heat sink approach. This
paper focuses on inline pin fin heat sink, which use copper material with different shapes of pin fin and a
constant 5.5W heat sources. The simulation model has been formulated using COMSOL Multiphysics
software to stimulate the pin fin design, study the thermal distribution and the maximum heat profile.
The document presents information on a bootstrap air cooling system suitable for aircraft. It consists of two heat exchangers, a secondary compressor driven by a turbine, and uses ram air and compression to cool and circulate air. Ambient air is compressed by the main aircraft compressor then cooled in an air cooler before further compression and cooling. It is then expanded through a turbine to provide cooled air to the aircraft cabin. Advantages are that air is readily available, non-toxic, and pressures are low. A limitation is that it requires aircraft flight for ram air cooling and is not suitable for ground use without an additional fan.
1. Combustion involves the rapid chemical combination of fuel and oxygen, resulting in heat release. It requires a combustible mixture, an ignition source, and flame propagation.
2. In spark ignition (SI) engines, a carburetor supplies an air-fuel mixture and a spark plug ignites it. Combustion in SI engines occurs in three stages: ignition lag, flame propagation, and afterburning.
3. Factors like air-fuel ratio, compression ratio, load, turbulence, and engine speed affect the flame propagation rate in SI engines. Higher propagation speeds improve efficiency and fuel economy.
Refrigeration and air conditioning systems work by removing heat from an enclosed space to lower its temperature below the surrounding environment. There are two main types of refrigeration systems - vapor compression cycles and vapor absorption cycles. Vapor compression cycles use a compressor, condenser, expansion valve, and evaporator to remove heat. Vapor absorption cycles use heat to drive the refrigeration process rather than electricity. Air conditioning systems build on refrigeration principles to simultaneously control temperature, humidity, air motion, and quality within an enclosed space.
Choosing the right Rubber Calender is important; learning to operate it smartly is equally key for your success with this machine. This edition covers all these aspects in a descriptive manner.
The document discusses OptiStruct, a structural analysis solver from Altair Engineering. It can analyze and optimize structural designs for strength, durability, and noise and vibration performance. It uses finite element analysis and multi-body dynamics techniques. The document also outlines an agenda covering new features like auto-contact detection, pretension management tools, and domain decomposition parallelization. It provides examples of using these new features to simplify modeling and improve performance on large models.
Moulds For Tyre Industries,Rubber Machine Mould Manufacturerjeykaveda
Welcome to S.R. Engineering,We are Manufacturers & Exports of Conveyor Manufacturer,Material Handling Equipment ,Re-conditioning & Refurbishment,Rubber Processing Machine,Mould For Tyre
Psychrometry and Air conditioning load estimationNITIN AHER
This document discusses psychrometrics and air conditioning load estimation. It covers topics like:
- The composition of air and properties of moist air like humidity ratio, enthalpy, specific volume.
- Psychrometric chart which graphically represents thermodynamic properties of moist air.
- Basic psychrometric processes like sensible heating/cooling, humidification, dehumidification.
- Methods to achieve these processes like air washers, evaporative cooling, steam injection.
- Factors affecting human comfort and the use of comfort charts.
- Estimating cooling loads for air conditioning systems.
Walk in cooler & freezer cold room plant & refrigerated cold storage warehous...svfd1721
This document provides instructions for the design, installation, operation, and maintenance of walk-in coolers and freezers. It discusses product information and applications, installation procedures, operational instructions, control settings, and maintenance guidelines. The document contains diagrams of electrical wiring and refrigeration systems. Maintaining proper temperature settings, cleaning, and routine maintenance are emphasized for optimal performance of walk-in cold storage units.
Blend
Up to 30 ingredients are used in your tyre’s rubber blend. The ingredient proportions will depend on what the performance goals of the tyre will be. It’s composed of several types of rubber, fillers and other ingredients, mixed in giant blenders known as Banbury mixers. These create a black gummy compound that’ll be sent on for
milling.
The Process of Making a Tyre - Banner 2Mill
Once the rubber is cooled, it’s sent to a special mill where the rubber is cut into strips that will form the basic structure of your tyre. At the milling stage, other elements of the tyre are prepared, some of which are then coated in another type of rubber.
The Process of Making a Tyre - Banner 3Build
The tyre itself is constructed, from the inside out. The textile elements, steel belts, beads, ply, tread, and other components are placed in a tyre-building machine that ensures every part is in its precise location. This results in what looks like a relatively finished product, known as a green tyre.
The Process of Making a Tyre - Banner 4
Cure
The green tyre is then vulcanised with hot moulds in a curing press, compressing all of the parts of the tyre together and giving the tyre its final shape, including its tread pattern and manufacturer’s sidewall markings.
A Stirling engine operates by compressing and expanding a gas between a hot side and cold side of a cylinder. The engine was invented in 1816 by Robert Stirling. It works based on the temperature difference between the two sides of its cylinder. The gas inside is moved between the hot and cold sides, expanding on the hot side and contracting on the cold side. There are different configurations of Stirling engines, including alpha, beta, and gamma types. The ideal Stirling cycle consists of four thermodynamic processes: isothermal expansion, constant volume heat removal, isothermal compression, and constant volume heat addition. Stirling engines can be used in submarines, for cooling rooms, in aircraft, and in boats
The document discusses the components and operation of an anti-lock braking system (ABS). It describes the key components of ABS including speed sensors that monitor wheel rotation, valves that control hydraulic brake pressure, a pump to supply pressure, and a controller that monitors sensor data and actuates the valves. It explains that the controller detects wheels that are slowing too quickly, indicating a risk of lockup, and uses the valves to reduce brake pressure to that wheel to maintain traction. Modern ABS and stability control systems apply this principle across all four wheels using individual wheel sensors and controls.
This document provides information about hydraulic and pneumatic braking systems. It discusses the principles and components of hydraulic braking systems, including drum and disc types. It explains that hydraulic brakes use pressurized brake fluid to apply equal braking force to all wheels. Pneumatic braking systems are also covered, noting that they use compressed air as the working fluid. The key components of a pneumatic system are described along with how the air pressure is stored and distributed to brake chambers to slow the vehicle. Advantages of both hydraulic and pneumatic systems are presented.
1) Group analyzed crashworthiness of a 1500 pickup truck through FE simulations of frontal impacts at 30 mph and 35 mph and an oblique 30 mph side impact.
2) Key results included barrier forces, displacements, velocities and accelerations which showed increased impact at higher velocity. Pole impact introduced most stress due to concentration.
3) Analysis provided understanding of FMVSS 208, NCAP tests and how vehicle and components absorb crash energy. Recommendations to improve model and validation were provided.
Thermodynamic Design of a Fire-Tube Steam BoilerJohn Walter
This document summarizes the thermodynamic design of a fire-tube steam boiler. It includes an introduction describing the key components of a fire-tube boiler. The design analysis section shows calculations for temperature distribution, heat transfer within the boiler, area for the second and third passes, and volume ratios. The design outcome provides the dimensions and specifications determined for the boiler, including a boiler length of 5m, diameter of 2m, and furnace diameter of 0.8m. Supporting data is also included in an Excel file.
The cylinder head determines key engine properties like power output, torque, and emissions. Cylinder heads require materials with high mechanical properties above 150°C due to the complex shapes and high stresses during operation. For passenger cars, aluminum is commonly used due to its properties, while cast iron is used for larger engines. Modern cylinder heads, especially for direct injection diesel engines, require alloys with high tensile strength, creep resistance up to 250°C, thermal conductivity, and ductility to withstand thermal stresses. Common casting methods include sand casting, permanent mold casting, lost foam, and pressure die-casting, using cast iron or aluminum alloys.
This document provides information on various plastic joining processes including ultrasonic welding, vibration welding, spin welding, and induction welding. It discusses the principles, advantages, disadvantages, applications, suitable materials, and design recommendations for each process. The key points are:
1. Ultrasonic welding uses high-frequency vibrations to melt plastic surfaces and join them. It is fast and economical but requires specifically designed joints.
2. Vibration welding generates heat through high-amplitude, low-frequency vibrations. It can join large parts but has initial high equipment costs.
3. Spin welding friction welds circular joints by rotating one part at high speed. It is simple and energy efficient but limited to circular
The document discusses the analysis of brake drums using finite element modeling. It begins by stating that brake drums experience high thermal stresses from braking and need to withstand both thermal and mechanical loads. Finite element analysis is used to accurately model stress distribution since an analytical solution is not possible due to complex loading conditions. The analysis focuses on an internally expanding brake drum used in medium-duty vehicles.
Structural modeling and meshing of blast furnace using TCL/Tk scripting.debiprasadghosh
The document describes modeling and meshing of a blast furnace structure using HyperMesh and finite element analysis software. Key steps include:
1. Creating the blast furnace geometry in HyperMesh using solid modeling techniques.
2. Generating a mesh and applying material properties, boundary conditions, and loads representing the blast furnace's operation.
3. Exporting the model to ANSYS and using Tcl/Tk scripts to automate running iterative simulations with modified parameters.
4. Viewing stress results in HyperView to evaluate design changes and optimize the blast furnace structure.
Recent advances in semiconductor technology show the improvement of fabrication on
electronics appliances in terms of performance, power density and even the size. This great achievement
however led to some major problems on thermal and heat distribution of the electronic devices. This
thermal problem could reduce the efficiency and reliability of the electronic devices. In order to minimize
this thermal problem, an optimal cooling techniques need to be applied during the operation. There are
various cooling techniques have been used and one of them is passive pin fin heat sink approach. This
paper focuses on inline pin fin heat sink, which use copper material with different shapes of pin fin and a
constant 5.5W heat sources. The simulation model has been formulated using COMSOL Multiphysics
software to stimulate the pin fin design, study the thermal distribution and the maximum heat profile.
This document describes finite element modeling techniques for simulating the thermal analysis of the electron beam melting (EBM) additive manufacturing process. It presents details on implementing both Abaqus user subroutines and a new Abaqus plugin called AM Modeler to model key phenomena in EBM, including a moving heat source, material state changes, and layer-by-layer deposition. Validation studies are performed and results from the user subroutines and AM Modeler are found to be in excellent agreement. A full 3D model is also developed to simulate the EBM printing of specific 3D objects. Source codes for the subroutines and AM Modeler implementation are made available to facilitate further research.
THERMAL ANALYSIS OF A HEAT SINK FOR ELECTRONICS COOLINGIAEME Publication
Heat transfer is a discipline of thermal engineering that concern the generation, use, conversion and exchange of thermal energy, heat between physical systems. Heat transfer is classified in to various mechanisms such as heat conduction, convection, thermal radiation & transfer of energy by phase change. Most of the electronic equipment are low power and produce negligible amount of heat in their operation. Some devices, such as power transistors, CPU's, & power diodes produce a significant amount of heat. so sufficient measures are need to be taken so as to prolong their working life and reliability.
This document discusses plasma assisted milling (PAM), a thermal enhanced machining technique where a plasma jet is used to heat the workpiece material ahead of the cutting tool. The plasma jet heats the surface to 400-1000°C, lowering the shear strength and cutting forces. Experimental PAM was conducted on difficult-to-machine alloys like Inconel 718 and Haynes 25 using tungsten plasma nozzles and infrared cameras to measure workpiece temperature. Results showed the alloys could be machined at higher speeds and depths of cut compared to conventional milling due to reduced tool wear from lower cutting forces at the heated surface.
IRJET- Thermal Analysis and Optimisation of Ceramic Heating Pads for Small Tu...IRJET Journal
This document discusses the thermal analysis and optimization of ceramic heating pads used for stress relieving small tubes. Ceramic heating pads contain nickel-chrome wire and ceramic beads for producing heat up to 1000°C. When used on small tubes, the flat ceramic beads do not allow for complete wrapping. Changing the beads to a curved shape allows for uniform heat transfer and easier wrapping on tubes as small as 30-100mm in diameter. Thermal analysis shows the curved beads can produce temperatures of 1200°C internally and 950°C externally, achieving the required stress relieving temperatures in a more efficient manner.
Analysis and Design Methodology for Thermoelectric Power Generation System fr...Omkar Kamodkar
This paper combines heat transfer and
thermoelectric conversion techniques to create a
thermoelectric generator device for a single-cylinder, fourstroke petrol engine. The system is made up of heat absorbers,
thermoelectric generator, Thermoelectric Generator (TEG)
modules, and an external heat sink. To achieve the goal of
absorbing heat and increasing thermoelectric conversion
efficiently, the heat exchanger surface area and heat-exchange
time could be increased. Thermoelectric generators convert
waste heat into energy directly. This technology will also help
energy conversion systems work better overall. Despite the
fact that TEG production is limited by available technologies,
feasible electricity generation is possible from waste heat
generated by automobiles. The effect of using passive heat
sinks and heat absorbers made of a flat plate with fins of
various cross-sectional areas and materials with forced
convection heat transfer, as well as how current, voltage, and
power are varied, is investigated and presented in tabular
format in the current numerical analysis. By plotting the
results of the analytical and numerical method on relevant
graph, the results of both methods were compared
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2. Testing of the system showed that connecting 4 thermoelectric modules in series generated a voltage of up to 1.74V with a temperature difference of 57°C across the modules. This demonstrates the feasibility of recovering some of the otherwise lost waste heat from engines.
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1. THE PROJECT ENTITLED
HEAT SINK USING ADDITIVE
MANUFACTURING
PREPARED BY
ANKIT SUTARIA 1001505011
UNDER THE GUIDANCE OF
DR. ROBERT. M. TAYLOR
DEPARTMENT OF MECHANICAL AND AEROSPACE
ENGINEERING
THE UNIVERSITY OF TEXAS AT ARLINGTON
2. HEAT SINK USING ADDITIVE MANUFACTURING
UNIVERSITY OF TEXAS AT ARLINGTON 2
TABLE OF CONTENTS
Introduction and Project Description 3
Additive Manufacturing Process Discussion 4
Component Design 6
Build Preparation 8
Build Execution and Post-processing 8
Conclusion 10
3. HEAT SINK USING ADDITIVE MANUFACTURING
UNIVERSITY OF TEXAS AT ARLINGTON 3
OBJECTIVE
To design a heatsink by implementing thermal topology optimization technique and manufacture
it using additive manufacturing to obtain complex geometry for convective heat transfer.
INTRODUCTION AND PROJECT DESCRIPTION
Additive Manufacturing (AM) is a layer-based approach used for the creation of parts directly
from Computer-Aided Design files. Rather than utilise subtractive methods to remove material
from a larger piece, parts are built by bonding successive layers of material typically through heat
input, a binder, or by chemical means. This approach made production of components with
complex geometries possible which were impossible to create using conventional manufacturing
processes. After decades of research additive manufacturing is now reached a stage of maturity
where additively manufactured parts are now compared to those well-established manufacturing
methods.
A heatsink are used to transfer heat of electronic or mechanical devices away from the device by
a fluid medium, often air or a liquid coolant. It transfers thermal energy from high temperature
device to low temperature device. Thereby regulating the device’s temperature at optimum levels.
For computing devices heatsink are used to cool CPU or GPU. It is also used in high power
semiconductor devices such as lasers and LEDs where component itself cannot moderate its
temperature. Heatsinks are designed such a way that it increases the surface area in contact with
the cooling medium surrounding it. The Most common heatsink materials are copper and
aluminium alloy with thermal conductivity of 401 and 237 [W/mK].
Historically, air cooling has been the preferred method to transfer heat due to its simplicity,
reliability, and lower cost of operation. Air cooling relies on the natural circulation of air caused
by density difference between hot air and the surrounding cold air environment. Figure shows
typically designed heatsink available in market for surface mount devices. The limitation with
these heat sinks is the surface area requirement of the design. The heat transfer rate can be
increased in these heatsinks by increasing surface area and applying forced convection, which will
end up consuming more space and external power requirements for fans also increasing the number
of fins in the same size of base area depends on the manufacturing device’s accuracy.
4. HEAT SINK USING ADDITIVE MANUFACTURING
UNIVERSITY OF TEXAS AT ARLINGTON 4
Topology optimization is a mathematical method used to obtain geometries which are objective
based such as minimizing thermal compliance, fixed volume contains, and boundary conditions
with the goal of maximizing the performance of the system. In this project Thermal topology
optimization is used to obtain the 3D geometry of the heat sink. An advantage of topology
optimization is that design concepts are produced quickly compared to the traditional approach of
using parametric analysis. Although the production of the optimized design is quicker, the obtained
design features may be complex to fabricate using conventional machining techniques. Thus, to
improve manufacturability, a fabrication constraint may be incorporated into the optimization
process. In some cases, even after applying a constraint, intricate designs may be challenging to
manufacture using conventional machining. To build complex parts, AM techniques are
considered.
ADDITIVE MANUFACTURING PROCESS DISCUSSION
The AM process required to produce copper heatsinks is Powder bed fusion process (PBF). Powder
bed fusion process does not require any support material as the powder in bed acts as a support
material. In metal PBF there are two processes, (i) Metal laser sintering (MLS) and (ii) Electron
beam melting (EBM). Metal laser sintering uses laser to melt the powder while EBM uses high
energy electron beam to fuse powder particles. This process was developed at Chalmers University
of Technology, Sweden, and was commercialized by Arcam AB, Sweden, in 2001.
Compared to MLS’s laser beam, the EBM process has more efficient electron beam gun. Which
is also more energy efficient than laser technology resulting less power consumption and lower
maintenance and manufacturing costs. The individual scan lines in EBM are indistinguishable
while in MLS the scan lines are easily distinguishable. Also, in MLS the bed is maintained at lower
temperature therefore elevated temperature grain growth does not erase layering effect. However,
in EBM the higher temperature of powder bed and the larger and more diffuse heat input result in
a continuous grain pattern. EBM parts are less porous than MLS microstructure. The residual
stresses are less in EBM parts than MLS parts. Less supports are required in EBM compared to
MLS. Due to these reasons EBM is selected for heatsinks over MLS.
The schematic diagram of EBM machine is shown in fig (b). EBM machine consists of filament,
grid cup, anode, focus lens-controls spot size, deflection lens-controls x-y motion, powder hopper,
vacuum chamber and build platform. The EBM machine selected to build the heatsink is Arcam
Q10 fig (a). The Arcam Q10 has maximum build size of 200*200*180 mm (W*D*H) which is
closest to the heat sink dimensions 100*100*100 mm.
The electron beam is generated in an electron beam gun at the top of vacuum chamber. The beam
is deflected using deflection lens to reach whole build area. Filaments emits the high temperature
electron which are then accelerates into electric field. Electron beam is controlled by two magnetic
5. HEAT SINK USING ADDITIVE MANUFACTURING
UNIVERSITY OF TEXAS AT ARLINGTON 5
fields which focuses the beam and deflects to desired point. Powder hopper spreads the powder
over the bed after each successive layer. Which is either by counter rotating roller or by a doctor
blade. The powder bed is maintained at high temperature for steady state uniform temperature in
the build tank resulting better grain structure.
EBM can produce parts faster by creating multiple melt pool and moving electron beam
instantaneously which can dramatically speed up production of overall product.
The EBM machine requires conductive materials which can transfer electricity faster so that the
powder particle should not become highly negatively charged. The geometry needs to be optimized
for EBM machine also it requires clean build place and proper placements of build on the start
plate. It requires proper vacuum chamber to manufacture the part.
Advantages of EBM
• Faster build speed due to high power
6. HEAT SINK USING ADDITIVE MANUFACTURING
UNIVERSITY OF TEXAS AT ARLINGTON 6
• Multiple melt pool can be achieved without moving parts resulting in high scanning speed
and low maintenance
• No impurities such as oxides and nitrides due to vacuum chamber
• Due to vacuum melt, high yield strength properties of the material
• Achieve high energy level in a narrow beam
Disadvantages of EBM
• Requires vacuum which increase cost of machine
• Post processing is required for better surface finish and for supports removal
• Only conductive materials are compatible
• Produces X-rays while in operation which requires shields inside vacuum chamber
Process Diagram
The above diagram consists of important part of the manufacturing process of heatsink. The CAD
file is generated according to heat transfer requirements and other specifications. After final CAD
odel is generated it need to be converted to stl file format. STL filr format does not contain
dimentions therefore before printing the part it need to be mentioned in the EBM machine. The
EBM machine generates the G-code for that stl file and determines the number of layers required
for print. The layer thickness and part orientation can be changes according to user requirements.
Then EBM machine starts to print the part and shows the estimated build time. After part printing
the part need to removed from the bed for post processing. After post processing the prt is ready
to be use for operation.
COMPONENT DESIGN
The heatsink need to be produce to increase heat transfer. Therefor the geometry of its stucture
does not matter as long as it improves heat within fixed design space. For the thermal topology
optimization Altair Hypermesh Optistruct solver is used. A 100*100*100 mm cube is taken for
primary part. Conduction and convection thermal analysis are solved by finite element method.
The heat flux and Conduction are applied on each face of each element. Temperature constraints
is applied on the small region of the bottom surface as 0C. The objective is implemented as
minimize the thermal compliance. The responses added are volume fraction(0.3) and thermal
compliance. After the optimization process the geometry of the heatsink was obatined wich is
CAD
convert to
STL
slicing and
GCode
preparation
EBM
process
Post
Process
Finished
Heatsink
7. HEAT SINK USING ADDITIVE MANUFACTURING
UNIVERSITY OF TEXAS AT ARLINGTON 7
shown in below fig. This geometry can only be produced by additive manufacuring due to its
complex branches like structure coming out of the body.
Boundry conditions
Optimized mesh geometry
8. HEAT SINK USING ADDITIVE MANUFACTURING
UNIVERSITY OF TEXAS AT ARLINGTON 8
BUILD PREPARATION
The above optimized CAD geometry was converted to STL file. The Stratasys uPrint machine was
used to make 3d printed part. The catalystEX software was used for slicing the STL file. the part
was scaled to 0.5% of the original vlume. The material used for the part and support was ABS.
estimated printing of the scaled down part was 6hour and 52 mins. The support structures ar
clearly visible in below figure in white color.
Stratasys uPrint SE part in slicing software
BUILD EXECUTION AND POST-PROCESSING
After all the settngs applied the machine was put to prin the part. The machine has two nozzles.
One foe build material and one for support material. as you can see in the below fig the layers are
clearly visible in printed part. The part still has the support structures around it. The post processing
of this part includes the support removal in chemical lye bath. The temperature of the lye bath is
set to 69C. The ly bath machine took arround 4 hours to remove supports from the part. as you can
see in below fig the part is finished and already has better surface finish. There is no need o do any
other post processing in the part.
9. HEAT SINK USING ADDITIVE MANUFACTURING
UNIVERSITY OF TEXAS AT ARLINGTON 9
Part Printing End of Part Printing
Lye bath Finished part
10. HEAT SINK USING ADDITIVE MANUFACTURING
UNIVERSITY OF TEXAS AT ARLINGTON 10
CONCLUSION
• In this project we discussed PBF process such as EBM and MLS.
• We compared both the process and concluded that EBM is appropriate for our part.
• The small branches of the Heatsink did not maintain to stay on the surface of the part
while post processing in the lye bath.
• While printing the FDM was not able to produce the infill correctly and some of the
portions of the part has both support material and part material printed into each other.
• We learned and saw how the parts are actually printed, why we require the support
material and how to remove these supports materials.
• Learned thermal topology in hypermesh optistruct and catalystEXsoftwares to generate
the topology and gcode file.
REFRENCE
• Dede, E. M., Lee, J., and Nomura, T., 2014, Multiphysics Simulation: Electromechanical
System Applications and Optimization, Springer, London.
• https://www.lboro.ac.uk/research/amrg/about/the7categoriesofadditivemanufacturing/po
wderbedfusion/
• Ian Gibson, David Rosen, Brent Stucker “Additive Manufacturing Technologies, 3D
Printing, Rapid Prototyping, and Direct Digital Manufacturing Second Edition”
• http://www.arcam.com/wp-content/uploads/Arcam-Q10.pdf
• Morgan Larsson, Ulf Lindhe, Ola Harrysson “Rapid Manufacturing with Electron Beam
Melting (EBM) – A manufacturing revolution?”
• https://images.google.com/
• Thermal Topology Optimization in OptiStruct Software by Xueyong Qu, Narayanan
Pagaldipti, Raphael Fleury, Junji Saiki
• Topology Optimization, Additive Layer Manufacturing, and Experimental Testing of an
Air-Cooled Heat Sink Ercan M. Dede, Shailesh N. Joshi and Feng Zhou