HINDUSTHAN COLLEGE OF ENGG AND TECHNOLOGY

APPLICATIONS OF FEA

SUBMITTED BY,

SHANKER.J(07ME55)

FINAL MECH-‘B’

APPLICATIONS OF FEA IN AEROSPACE ENGINEERING

The Aerospace Industry produces some of the most sophisticated, highly-engineered systems in the world today. Products must meet exacting standards for performance and safety. However, they must also be innovative and affordable to succeed in the marketplace.

To share the costs and the risk of development, manufacturers partner ever more closely with their global supply chain to produce:

Aircraft (military and commercial; fixed-wing and rotary-wing; fighters and freighters)

Aircraft engines (turbojets, turbofans, turboprops, turboshafts)

Spacecraft and missiles (expendable launch vehicles, reusable launch vehicles, satellites, space stations, rocket engines, surface-to-surface missiles, surface-to-air missiles, air-to-air missiles, air-to-surface missiles, ballistic missiles)

Physical testing of these systems is expensive and often dangerous. Today, many companies rely on computer-aided engineering (CAE) software from ANSYS to accurately simulate aerodynamics, engine performance and other mission critical behavior. ANSYS software integrates and couples comprehensive multiphysics capabilities featuring computational fluid dynamics (CFD) and finite element analysis (FEA) for high fidelity simulations such as:

Cooling of avionicsDynamic stresses in flexible, moving parts like landing gear

Fluid structure interactions (FSI) of high-speed flows with lightweight structures

Modal analyses and rotordynamic analyses of rotating engine parts

Optimization of electromagnetic actuators in the “all-electric airplane” and many other applications

Performance analysis of flow through multiple blade rows in engines

 

Thermal stress analyses of combustors, turbines, heat shields, anti-icing systems, and other hot components

This unequaled depth and unparalleled breadth of application is made possible with ANSYS preprocessing, CFD and FEA software featuring ANSYS Mechanical, ANSYS Multiphysics, ANSYS ICEM CFD, ANSYS ICEM CFD Cart3D, ANSYS CFX, FLUENT, ANSYS TAS, and other application-specific products such as ANSYS BladeModeler, ANSYS TurboGrid, ANSYS AUTODYN, ANSYS LS-DYNA and ANSYS Icepak.

Simulation Driven Aircraft Development In the past decades, aircraft development has been completely revolutionized. The aircraft industry has been challenged as a whole by numerous constraints such as currency fluctuations, safety regulations, fuel prices or new materials. The integration of enterprise-wide technologies such as computer-aided design (CAD) and product lifecycle management (PLM) has accelerated the overall design process.

It is clear that simulation - and more generally computer-aided engineering (CAE) - is a cornerstone of current technological advances. The challenge is to accurately predict the performance of the complete vehicle. The vehicle itself is comprised of sophisticated subsystems such as:

Airframes and aerostructures, including compositesAircraft engines (turbojets, turbofans, turboshafts, turboprops,

internal combustion engines)

Auxiliary power units (APU’s)

Avionics

Environmental control systems

 

Flaps and high-lift devices

Flight control systems

Inlets, diffusers, nozzles and thrust reversers

Landing gear

Propellers

Pylons and nacelles

Rotors (rotary-wing aircraft)

Safety systems, including anti-icing and de-icing equipment,  pilot ejection systems and fire suppression systems

Store separation systems (for military aircraft)

Wings and aerodynamic sections

Companies are integrating simulation at all stages of the design process, putting the design at the heart of a virtual environment. This is what Simulation Driven Product Development is all about.

As the pioneer of Simulation Driven Product Development , ANSYS helps aircraft companies achieve their goal of zero-rework, accelerating even further the development process and reducing design cost while enabling innovation, creativity and quality.

In order to do this, ANSYS provides the most comprehensive and advanced simulation portfolio available, enabling true multi-disciplinary optimization (MDO). The portfolio is comprised of well-known finite element analysis (FEA) and computational fluid dynamics (CFD) software including ANSYS Mechanical, ANSYS Multiphysics, ANSYS ICEM CFD, ANSYS ICEM CFD Cart3D, ANSYS CFX, FLUENT, ANSYS TAS, and application specific products such as ANSYS TurboGrid, ANSYS BladeModeler, ANSYS AUTODYN, ANSYS LS-DYNA and ANSYS Icepak.

 

Aircraft Engines and Gas Turbines Large and small aeroengines, aeroderivatives, auxiliary power units and industrial gas turbines play an important role in the transportation and power generation industries. Customers now require manufacturers to deliver technologically advanced, efficient and better performing products which meet new standards in terms of increased reliability, reduced cost, lower fuel consumption, reduced emissions and low noise. Global competition is intense and the ability to deliver superior machines ahead of the competition is essential for survival. Leading manufacturers have adopted Simulation Driven Product Development from ANSYS as a key enabler for meeting these demanding goals.

ANSYS computer-aided engineering (CAE) software is used for a wide range of gas turbine applications, including:

Aircraft engine fan Combustor analysis

Compressor and turbine bladed flow path computational fluid dynamics (CFD) analysis

Cavity analysis

 

Heat transfer and thermal stress analysis

Inlet and exhaust diffuser analysis

Under-cowl fluid flow and heat transfer management

Installation aerodynamics

Rotordynamic and bearing analysis

Secondary flow path analysis

Structural and modal analysis of all components (finite element analysis, or FEA)

Turbine blade cooling, film cooling and durability studies

The unequalled depth and unparalleled breadth of ANSYS products provides designers and analysts with the greatest range of functionality, applicable to all of the complex physical phenomena encountered in modern gas turbine engines. For instance, the ANSYS computational fluid dynamics (CFD) solvers ANSYS CFX and FLUENT provide all the necessary turbulence and combustion models for high-fidelity simulation of steady and unsteady, rotating and stationary frame, swirling, accelerating, diffusing, combusting, subsonic and supersonic flows with shocks, mixing and sprays. Similarly, ANSYS Mechanical, ANSYS Multiphysics, ANSYS AUTODYN and ANSYS LS-DYNA provide designers with with the necessary tools for linear and non-linear stress analysis of simple and composite materials, contact, dynamics, rotordynamics, conjugate heat transfer and thermal stress analysis.

ANSYS gas turbine tools are part of the ANSYS Workbench environment, ensuring start-to-finish, multiphysics workflow and seamless CAD connection. Productivity-enhancing tools such as ANSYS ICEM CFD, ANSYS TurboGrid and ANSYS BladeModeler, as well as turbomachinery-specific pre- and post-processing deliver true Simulation Driven Product Development performance in a flexible, open environment.

Spacecraft and Missiles The Spacecraft and Missiles Industry is one of the most difficult in which to compete. The industry’s successes and failures still make headlines today, and their accomplishments have earned rocket scientists worldwide acclaim.

As demand for commercial use has grown and the industry has matured, competition has also increased. Launch vehicles, engines and satellites are produced worldwide. Launch services are offered globally. Innovative concepts featuring different tradeoffs continue to be developed. Vehicles can be manned or unmanned, expendable or re-usable, launched vertically or horizontally, from the ground or in the air.

Operational conditions and engineering challenges are extreme. A multitude of parts must be designed, engineered and integrated to reliably survive the rigors of space:

Avionics and electronicsBraking systems

Environmental control systems (payload environments, cabin

 

environments)

Ejection systems and escape modules

Fuel systems and fuel management

Landing gear

Rocket engines (solid rocket motors, liquid rocket engines, various hybrid engines)

Gas turbine engines are also used to power air-borne missiles.

To engineer and develop reliable systems for these extreme environments, the industry has used computer-aided engineering (CAE) simulation software for decades. With each advance in high-performance computing, virtual prototypes become more and more detailed and increasingly accurate. Today, expensive physical testing is focused more on validating final designs rather than on improving designs.

Comprehensive multiphysics from ANSYS enables virtual prototypes to account for Fluid-structure interactions of lightweight structures such as folded solar panels of satellites in environmentally controlled payload compartments; thermal stresses in combustors, heat shields, turbine blades, and other components subjected to extreme temperature gradients; and other multi-disciplinary phenomena. These challenging problems become tractable using integrated, advanced technologies from ANSYS such as finite element analysis (FEA), computational fluid dynamics (CFD) and more. ANSYS products renowned in the industry include ANSYS Mechanical, ANSYS Multiphysics, ANSYS ICEM CFD, ANSYS ICEM CFD Cart3D, ANSYS CFX, FLUENT, ANSYS TAS, and other application-specific products such as ANSYS BladeModeler, ANSYS TurboGrid, ANSYS AUTODYN, ANSYS LS-DYNA and ANSYS Icepak.

APPLICATIONS OF FEA IN AUTOMOBILE INDUSTRIES

Growing scrutiny of pollution caused by vehicles, compounded by the rise in oil prices, has increased the emphasis on product innovation in this highly competitive global industry. The most successful companies are differentiating themselves by employing new simulation technologies in the earliest stages of design to reduce development cycles and lower costs. 

However, the geometric complexity and advanced physics involved in the modern automobile present some of the most challenging CAE problems faced by engineers today. Market pressures to create innovative products in less time emphasize the need to carry out more advanced simulations, faster than ever before. ANSYS is leading the way with software products that provide fast, accurate solutions in a broad range of physics including structural, thermal, electromagnetics and fluids. We offer a comprehensive set of automated CAD-associative meshing tools fully integrated with advanced physical modeling capabilities enabling you to understand product performance and optimize designs, long before a prototype is ever built.

As the largest provider of Simulation Driven Product Development tools, ANSYS is helping leading companies master the integration of simulation to develop design concepts into top-selling products. Simulation tools from ANSYS are widely used in the automotive, commercial, recreational vehicle, motorsports and construction equipment industries for:

AerodynamicsBody in white

Chassis

Climate control

Engine design

Manufacturing processes

Noise, vibration and harshness (NVH)

Powertrain

Thermal management

 

Vehicle components

 

Vehicle AerodynamicsThe external shape of a vehicle not only needs to be attractive and represent a brand- specific design, it also has to be fuel efficient and ensure driving stability at high speeds.

Achieving a balanced distribution of aerodynamic lift and drag, the optimization of cooling openings, reducing noise generation, controlling rain water and avoiding dirt accumulation in critical areas are only a few goals of aerodynamic design and development. Time-dependant effects, generated during overtaking, might need special attention. Parts may deform due to aerodynamic loads, requiring a coupled treatment of fluid and structural elements.

ANSYS, Inc. provides all the tools necessary for upfront design, targeted optimization and virtual validation in a unique, integrated environment. Read more on how the ANSYS tools assist in automotive design and help to reduce the number of physical prototypes.  

Body-in-WhiteAutomotive manufacturers are continuing to reduce the weight of passenger cars to meet the increasing government regulations on fuel efficiency and CO2 emissions. The body-in-white is a vehicle’s largest structure, and therefore ideal for weight reduction considerations.  However, reducing body weight involves a trade-off with body stiffness, a key characteristic which

 

influences vehicle dynamics, durability and crash worthiness.

A simulation driven approach to designing the body-in-white is paramount in today’s competitive automotive industry. The unequalled depth and unparalleled breadth of the ANSYS product line provides effective, industry-proven tools to evaluate and optimize a vehicle’s structural components. From geometry repair tools like mid-surface extraction to special elements for spot welds to high performance numerical methods for large models, ANSYS, Inc can provide the software and expertise to enable your organization to arrive at the best body-in-white design faster.

Vehicle Chassis

Modern vehicle chassis are complex assemblies with various multi-domain design requirements. Lightweight monocoque bodies provide stiffness for ride and crashworthiness objectives. An assortment of suspension elements like coil springs, control arms and steering linkages dictate the vehicle's handling. Rubber bushings and dampers reduce vibration transmission and increase comfort. What is needed is a simulation environment capable of delivering all the necessary physics and analysis types required to optimize and evaluate the system against the myriad of design objectives. Within ANSYS Workbench, chassis engineers can perform kinematic analyses of suspension sub-systems, nonlinear finite element analysis of elastomer mounts, frequency response to road loads and power train vibration, or static stiffness and modal analyses of the primary structural components. Imagine the increase in productivity if these analyses and more were conducted in a single environment without transferring models and data between disparate

 

applications. This is today's ANSYS Workbench.

Climate ControlPhysical comfort when driving is a very important customer criterion. Human comfort is a subjective perception, influenced by a number of physical state variables. Besides standard heating, ventilation and air-conditioning for thermal comfort, a passenger’s sense of well-being can be affected by noise and solar radiation. Furthermore, reliable defogging and defrosting are essential for the safety of the vehicle’s occupants.

Experimental investigation of a cabin interior is very difficult because of low velocites and small temperature variations in a highly complex geometry. Additionally scale models are not well suited to deliver meaningful results for such a case, only real-car tests can offer significant understanding. Especially in early design stages the expenses associated with mock-ups and prototypes are prohibitive.

Hence simulation is the most efficient approach to obtain maximum comfort by optimizing flow and air quality, increasing equipment life, and providing for thermal and acoustics distribution while minimizing pressure and energy loss. ANSYS, Inc. provides all the tools necessary for such an upfront design, targeted optimization and virtual validation in a unique, integrated environment. Read more on how the ANSYS tools assist in cabin interior and systems design for passengers feeling well.

 

Applications of fea in marine fieldANSYS is a powerful engineering software tool that can be used to simulate many types of industrial flow and heat transfer processes.

ANSYS has provided advanced computational fluid dynamics technology to the Marine Industries for many years. ANSYS CFD solutions have been used to:

Analyze the unsteady flow behind a propeller in order to:o decrease noise

o decrease vibration

o predict stress

o assist in scale-up

o optimize design

o decrease energy requirements

Perform fire simulations for:

o safety

o fire suppression

Assist in design optimization for all kinds of rotating equipment including pumps, fans and compressors

Analysis of fuel/water mixing in ship compensated fuel/ballast tanks to reduce the potential for pollution during refueling.

Propellers and Propulsion

Engineering simulation of marine propulsion is a challenge: The marine environment's operating conditions are complicated, and simulating the physics of this environment is complex. It may involve an understanding of a wide range of simulations including structural analysis and computational fluid dynamics. In addition, the interaction between the ship and propeller is extremely important for overall design efficiency.

Designing ships is not a straight-forward process. Design changes are frequent and prototyping can be quite expensive. Simulation-driven design can be extremely effective in designing vessels that mitigate risk -- helping engineers make critical decisions throughout the design process. ANSYS provides a wide variety of tools that can be used to simulate propulsion equipment; the impact of waves, wakes and collisions; and maneuverability.

Hulls

A fundamental concern of naval architects is storms and the extreme stress they put on a ship's structure. Engineering simulation during the design phase of these vessels can decrease risk and deliver greater structure integrity, while at the same time delivering a design that meets market demands.  All of ANSYS' structural analysis tools can be used to help achieve this goal.

In addition, computational fluid dynamics tools from ANSYS provide capabilities including turbulence and free surface models to assist in improving stability and increasing speed.

Applications of fea in chemical engineering

Chemical (CPI), petrochemical (HPI), refining and other process industry companies are responding to issues such as green engineering, energy reduction, sustainability, environmental impact, corporate profitability and global competitiveness through innovation and the use of advanced engineering and technology. ANSYS software and simulation technology, including fluids (CFD) and structural (FEA), is routinely used alongside experiments, correlations, and other analysis methodologies to help engineers better understand the product and processes.

The recent advances in modeling capabilities, combined with scalable low-cost, high-performance hardware, has opened new reliable ways for design, manufacturing, operation and optimization of process equipment including reactor design, pollution control, thermal and energy management, safety and structural viability, as well as product quality and process efficiency.

Learn how ANSYS solutions are used in:

Heat generation and heat transfer equipmentMixing

Multiphase systems

Process equipment

Reactor design

Separation, filtration and distillation

For more than 30 years, ANSYS has provided simulation technology and expertise to engineers, designers and researchers, driving the concept of Simulation Driven Product Development. ANSYS develops integrated and easy-to-deploy software tools that fully meet the engineering need of applications in the process industries. The insight gained using these simulation tools reveals opportunities for increased capacity, regulatory adherence, improved product quality, lower energy costs, downtime management and increased throughput. This leads to the ability to optimize process and equipment performance, to shorten design cycles, to reduce capital investment and to troubleshoot risks.

Heat Generation and Heat Transfer Equipment

Burners, furnaces, incinerators, process furnaces and regenerators have been studied by power generation companies using engineering simulation tools as far back as the early 1980s. The combustion of fuels (gas, liquid and solid) along with other sources of heat (nuclear, electrical and chemical reaction) has also been well studied and modeled. ANSYS engineering simulation software has an unparallel depth of capabilities to simulate these types of applications, as well as ones such as combustion chemistry, species reaction and heat transfer, thermal stresses and phase change.

Heat transmission by conduction, convection and radiation in laminar or turbulent flows for fluids such as steam, thermal liquid, liquid metals and non-Newtonian fluids, can be simulated using ANSYS software. This type of simulation is often performed to account for hot spots, associated thermal stresses, equipment design and process efficiencies, that can effect flow and geometry considerations.

Independent of whether your heat transfer equipment is designed by type or function, you can gain insight, improve performance and select the right design for the right application by using ANSYS engineering simulation technologies. For example, using

the pressure vessel model in ANSYS software helps you in the construction, material selection and code requirements for boilers, storage tanks and tubes. Similarly, heat exchangers and tubular reactors are studied with ANSYS CFD to understand the effect of flow distribution, header designs, fouling and the best placement of baffles and support systems. ANSYS structural software is used for manufacturing, safety and fabrication studies.

Chemical, petrochemical and refining engineers, as well as equipment designers, know how to best use every BTU of available heat in their processes. With the current emphasis on energy efficiency and business pressures to improve margins, ANSYS multiphysics software tools provide a well established engineering platform to help improve the design and analysis of energy saving concepts, equipment reliability, structural integrity and related efficiency gains through virtual prototyping in a broad range of heat transfer equipments including:

Air-cooled heat exchangers

Boilers

Burners

Chillers

Condensers

Evaporators

Flares

Heat transfer from solids

Heaters

Heating and cooling tanks

Plate type exchangers

Reboilers

Shell and tube heat exchangers

Superheaters

Mixing

Over the past few decades there has been much progress in understanding mixing with the help of advances in computerized measurement and simulation techniques. The use of engineering simulation as an integrated part of computer-aided engineering (CAE) brings advanced virtual prototyping to the mixing application area to predict and understand flow-dependent processes. In many mixing applications, simulation is proving valuable in order to gain insight into how to increase product quality, enhance vessel performance, reduce waste and cost and improve time to market.

Today, a wide range of applications including, scale up, solid suspension, heat transfer, reaction and fermentation are modeled

using ANSYS fluid mixing technology. In addition, by using ANSYS multiphysics capabilities, many aspects of the structural mechanics of a mixer, including the shaft vibration, upset conditions, structural forces, the design of the gears and shafts and power reduction, can be better understood and optimized. ANSYS mixing simulation tools are used to help evaluate key mixing parameters, such as blending time, circulation and the power number in agitated mixing vessels for any configuration of impellers and mixing conditions, shaft orientations, and for any vessel geometry.

Beyond stirred tanks, mixing remains an important component of many processes. ANSYS simulations can offer a detailed understanding of tee mixers, jet mixers, as well as the mixing of polymers or multiple streams. ANSYS is dedicated to helping engineers better understand mixing applications. This dedication has resulted in ANSYS developing mixing centric advancements such as a mixing specific intuitive graphical user interface that has a mixing and process engineering focus, a set of advanced models that account for particle dispersion, complex impeller rotation, the ability to resolve micro and misso-mixing scales, complex rheology and the non-Newtonian fluids for creeping or highly viscous flows.

Today, process engineers all over the world are using engineering simulations tools from ANSYS to meet their varied mixing needs, such as:

Blending

Cell-culture grow

Crystallization

Emulsion

Fermentation

Gas dispersion

Gas-sparging

Glass-lined reactors

High shear mixers

Hydrogenation

Jet mixers

Laminar mixing

Liquid-liquid mixing

Mixing of food

Mixing vessels design: tank shapes, impeller type and placement, baffling level, type

Polymerization

Residence time distribution

Scale-up

Solids suspension

Static mixers

Water treatment

Multiphase Systems

Many applications in the process industries involve multiphase flows. The sustained and substantial investment in advanced technology development from ANSYS, combined with an ongoing focus in user-driven physical model development, play a key role in helping engineering simulation tools from ANSYS gain broad traction with researchers, process engineers and equipment designers. ANSYS provides an unparalleled depth of capabilities for modeling multiphase systems, including free surface, boiling, cavitations, wet steam, flashing, slurries and particulate systems.

The applicability of ANSYS engineering simulation tools to the process industry is achieved through the development of capabilities tailored to meet multiphase modeling needs. For example ANSYS tools allow engineers to model particle size distribution through population balance, this combines detailed fluid mechanics analysis with a better description of the size distribution of particles, bubbles, or droplets in a multiphase mixture. Using this formulation accounts for phenomena such as nucleation, growth, dispersion, dissolution, aggregation and breakage. By employing ANSYS tools it is now possible to describe and track changes in the particle population.

Similarly, for particulate laden flows, ANSYS provides simulation capabilities for a wide range of applications from diluted and high solid loading, to frictional flows. Because the applications of gas, solid and particulate flows are very diverse, ANSYS software tools provide a range of capabilities including discrete particle models (DPM), a macroscopic particle model (MPM), a smooth particle hydrodynamic (SPH) and full Euler-granular models. These models allow for the presence of large particles where particle collisions, rotation, adhesion, and other forces are

accounted for using a hard sphere approach.

For example, ANSYS fluid mechanics software has a well established track record of being used to help analyze and design the flow and performance of systems including:

Bag filters

Bubble columns

Centrifugal extractors

Crystallization

Cyclone separators

Decanters

Droplet separation

Dust collection

Emulsion

Fluidized bed catalytic cracking (FCC)

Fluidized-bed systems

Foams

Hydrocyclones

Process Equipment

Process equipment designers, manufacturers and operators are challenged every day to transfer, mix, separate, heat, distil, combust, react, store, package and extend the life of some of nearly 70,000 products that the chemical and processing industries provide. By using large amounts of heat and energy to mechanically or chemically transform materials, these industries help meet the world's most fundamental needs for food, shelter and health, as well as create products that are vital to such advanced technologies such as computing, telecommunications and biotechnology.

Engineering tools from ANSYS are used for Simulation

Driven Product Development (SPDM) in order to help accelerate design, provide insight, make processes more energy efficient, safer and more flexible, reduce emissions and improve reliability. The solutions from ANSYS cover all engineering aspects of product design, including structural and fluid mechanics, thermal, species reaction and transport, electromagnetic, fluid structure interaction, material effects and even impact and explosion. The full capability, multiphysics solutions from ANSYS allow you to address CFD, FEA and other CAE concerns in a single integrated environment from CAD import to prove of concept, prototyping, final design validation and manufacturing.

The combination of diverse full functionality, advanced technology, and ease of both use, and deployment, in ANSYS engineering software has brought the power of virtual prototyping, once thought to be used only for planes and automobiles, to process engineers and equipment designers.

Reactor Design

Chemical reactors are said to be the heart of a chemical plant. The chemical reactor is where high value products are produced through chemical transformation. Reaction engineers are concerned with the reactor yield, selectivity, safety, environment, product quality and purity, and plant economic viability of many different types of reactors, products and operational conditions. ANSYS engineering simulation software provides reliable tools to complement conventional reaction engineering practices. By bringing comprehensive multiphysics capabilities to reaction engineering, ANSYS has created an engineering simulation platform that encompasses, fluid mechanics, structural mechanics, impact and safety analysis, mixing, pressure vessel code, heat and mass transfer and gaseous and liquid reaction involving single and multiphase, including homogenous and heterogeneous reactions.

Advances in CFD and computational speed, as well as the ability to model complex reactions such as detailed fluid mechanics, has made virtual prototyping a norm

in many engineering circles. This is especially true in scale-up studies and for applications where approximations of well-mixed CSTR and plug flow assumptions do not hold. In addition, ANSYS simulation tools provide engineers the answer to "what if" questions to allow them to optimize reactor performance by better understanding processes such as the feed location, the effect of vessel geometry and its internals, vibrations, failure analysis, "dead spots", shear rate, resident time distribution, hot spots and particle size distribution.