Week 8 - Challenge 1 - Draft Analysis on a Fan Cover

AIM Create the Coin Holder Plastic component through the given Class-A surface. To begin with, the tooling axis for the given Class-A Surface should be created meeting the requirements of the draft angle and at the end perform the Draft analysis on the model. Take the Thickness of the component to be 2.5 mm Import…

CORE AND CAVITY DESIGN OF A SWITCH BEZEL AIM: To Create the Switch Bezel Plastic component through the given Class A surface. To begin with, the tooling axis for the given Class A Surface should be created meeting the requirements of the draft angle and also Create the Class B Surface & Class C Surface. At the end…

DRAFT ANALYSIS OF CENTER CONSOLE COIN HOLDER AIM: To create the center console coin holder plastic component through the given Class A surface and at the end performing the draft analysis on the model. OBJECTIVE: To ensure proper tree structure is followed. Geometrical sets should have a proper name based on the sketches…

SWITCH BEZEL DESIGN Aim-To create the switch bezel plastic component through the given class-A-surface and at the end performing the draft analysis on the model. Objectives- To ensure proper tree structure is followed. Geometrical sets should have a proper name based on the sketches present inside of it. All the sketches…

OBJECTIVE- Create the Base Bracket Plastic component through the given Class-A surface. To begin with, the tooling axis for the given Class-A Surface should be created meeting the requirements of the draft angle and at the end perform the Draft analysis on the model. DETAILED REPORT- Terms Used- Class 'A' Surface- Class…

AIM: To create the tooling axis for the given Fan cover model meeting the requirements of the draft angle and performing the draft analysis on the model. OBJECTIVE: To ensure proper tree structure is followed. Geometrical sets should have a proper name based on the sketches present inside of them. All the sketches should…

Aim: To mesh the hood geometry of a car with the given quality criteria. Objective: Target Element Length = 5 Units S.No. Quality Criteria  Value  1 Aspect Ratio  5 2 Skewness 45 3 Warping 15 4 Taper      0.5 5 Min. Length 2 Units 6 Max. Length 8 Units 7 Min angle Quad 45 8 Max angle…

Aim: To mesh the side door- inner panel geometry of a car with the given quality criteria. Objective: Target Element Length = 4 Units S.No. Quality Criteria  Value  1 Aspect Ratio 1 5 2 Skewness 45 3 Warping 15 4 Taper      0.5 5 Min. Length 2 Units 6 Max. Length 6 Units 7 Min angle Quad 45 8 Max…

Aim: To mesh the rear wheel holder geometry of a car with the given quality criteria. Objective: Target Element Length = 5 Units S.No. Quality Criteria  Value  1 Aspect Ratio  5 2 Skewness 45 3 Warping 15 4 Taper      0.5 5 Min. Length 2 Units 6 Max. Length 8 Units 7 Min angle Quad 45 8 Max…

Aim: To mesh the given geometry with the provided quality parameters and to create connector by attaching various parts of the model. Objective: Target Element size - 5 Units S.No. Quality Criteria  Value  1 Aspect Ratio  5 2 Skewness 45 3 Warping 15 4 Taper      0.5 5 Min. Length…

Aim: To perform 3D meshing for the given components with the required element sizes and quality criteria. Objective: Create a Tetra mesh for Housing component with the following quality criteria. Elements sizes: Min- 2 Units, Target- 5 Units, Max- 7 Units  Tet collapse: 0.15 Note: The minimum length and the maximum…

Aim:         To mesh the given component with the size of 5mm. Create 1D elements on the following component with given cross-section and DOF. Objective: a. Rod element: - Translational DOF should be Constrained with RBE2 link Cross-Section: BOX- Dimension a= 12 mm    …

Aim:        To perform a parametric study using 3 different values of thickness for the car body. Objective: To analyse the Total Deformation and Equivalent Stresses acting on the model.  Procedure: At first, we will import the geometry model into ANSYS-WORKBENCH and for this model we will be providing…

Aim:         To simulate a bullet penetrating into a bucket in ANSYS-WORKBENCH. Objective: We must use 3 different nonlinear materials for the bucket and analyse their behaviour for the same velocity of bullet. Attach an animation to show the behaviour in the three cases.  Procedure:…

Aim:         To perform explicit dynamics simulation of a cutting tool on a workpiece. Objective: We will have to perform an explicit dynamics simulation to find out the Equivalent Stress, Total Deformation and also insert a User defined result to calculate the temperature of the body.…

Aim:         To perform the tension and torsion test on the specimen provided in explicit dynamics. Objective: For the tension test, displace one end of the specimen to 18 mm while keeping the other fixed. You will need to find out the total deformation, equivalent stress and temperature…

Aim:         To perform a transient structural analysis on a worm gear assembly. Objective: We will have to rotate the worm so as to get to almost end of the half cut and get results for Equivalent Stress, Equivalent Elastic Strain and the Total Deformation in the model. Procedure: At…

Aim:         To perform a transient structural analysis on a double universal joint with a spring in ANSYS-WORKBENCH. Objective: There must be three materials used on the joint with the springs alone and the materials are Structural Steel, Stainless Steel and Titanium alloy. Procedure:…

Aim:         To perform a transient analysis on a piston and cam mechanism model. Objective: to run the analysis with Frictionless contact, Frictional with 0.1 and 0.2 as the frictional contact for a total of 3 cases. Find out the Equivalent Stress, Directional Deformation and Equivalent…

Aim:         To simulate the bending of iPhone model as per the given conditions in ANSYS-WORKBENCH. Objective: Case 1: Simulate the model without fatigue life. Case 2: Move the bottom fingers from their defined position to the given position X= 22.5mm & Z= 10mm and obtain…

Aim:         To perform an analysis to simulate the bending of a wire in ANSYS-WORKBENCH. Objective: We will be using Copper Alloy (Non Linear), Aluminium Alloy (Non Linear) and Magnesium Alloy (Non Linear) for the wire alone and we need to find out the Equivalent stress and Equivalent…

Aim:         To simulate the rolling operation on a workpiece made of copper. Objective: Increase the length of the workpiece by 60 mm and decrease its size on both sides by 8 mm. Run the simulation for 14 steps and you can give small but random values for the displacement. Ensure that…

Aim:         To simulate three different types of welding using three different weld materials. Objective: Weld Material used: Case 1.  Stainless Steel: In this case, the material of the plates must also be the same. Use Stainless steel for both weldments and plates. No need to add…

Aim:         To perform sheet metal bending for 3 different materials mentioned with a variation of certain settings is also to be performed in ANSYS-WORKBENCH Objectives: Case 1: Aluminium Alloy 1199, Copper Alloy NL and Magnesium Alloy NL. Find out the Equivalent stress, Equivalent elastic strain…

Aim: To perform a static structural analysis on the Rail wheel and Track setup. Objective: Case 1: Multiply the bearing load by 5 times and compare the results with the load of 100000 N (As done in week 2 video). Compare the Total Deformation, Equivalent stress and the life under both the loads Case 2: Implement…

Aim: To write a few words about grid dependency test and to perform the same on bevel gear simulation. Objective: 1. Write a few words on what a grid dependency test is and its use.2. Perform a grid dependency test for the Bevel gear simulation for mesh sizes of 6, 5 and 4 mm.3. Solve for Von-Mises stress, Equivalent elastic…

Aim: To write a detailed report on the static structural analysis on a spur gear using materials and conclude which material would be recommended based on the results in ANSYS-WORKBENCH Objective: Case 1:                    Using Cast Iron (ductile) as a material, carry…

Aim: To design two plates with a hole or many holes model with the given dimensions and to determine the maximum deformation and stress developed in those two models in ANSYS-WORKBENCH Objective: Compare the deformation and maximum stress developed on a structural steel model for the 2 cases. From an analysis standpoint,…

Aim: To summarize about thermal management techniques for electric car battery pack. Theory: A battery pack is one of the most important and expensive components that is used in a HEV, EV and PHEV. The batteries used fall in to the category of secondary type meaning that they are rechargeable and are all based on lithium…

Aim:             To apply connections for the given rear door FE model, and to explain about the different connections used for the model in ANSA using the concepts of CAE. Procedure: Importing the file: Since the model is in .nas format which is NASTRAN solver format,…

Aim:         To understand battery technology in general and the different types of lithium ion cells. Objective:         To prepare a table which includes materials & chemical reactions occurring at the anode and cathode of LCO, LMO, NCA, NMC, LFP and LTO type of lithium ion…

Aim:        To simulate the generic battery model charge and discharge using UDDS data in MATLAB. Theory: Drive Cycle: A driving cycle is a series of data points representing the speed of a vehicle versus time. Driving cycles are produced by different countries and organizations to assess the performance…

Aim:          To make a MATLAB model of fuel powered electric vehicle and comment on the results. Theory:           A fuel cell is an electrochemical device that generates electricity by consuming a fuel. A fuel cell is one of the various…

Aim: Brief about coulomb counting and how BMS implements coulomb counting for SOC estimation. Theory: State Of Charge estimation is a key factor for correct and safe battery management, particularly for the development of the Battery Management System (BMS). In general, the SOC of a battery is defined as the ratio of its…

Aim: How weakest cell limits the usable capacity of the battery pack? What is the solution? Model: MULTI CELL BATTERY PACK: The performance of electric vehicles (EVs) and plug-in hybrid electric vehicle (PHEVs) strongly relies on their battery storage system, which consists of multiple battery cells connected in series…

Model 1: Under the condition of braking, some amount of energy is required to do the same as that of energy required for accelerating the vehicle. Hence to calculate energy, we use the acceleration energy equation, `E_k = 1/2 *m *v^2` Calculating the energy required for braking for a defined drive cycle: Drive cycle: Follow…

Aim:         To study about Speed control of a DC motor using BJT H-bridge and the Four-Quadrant Chopper DC Drive (DC7) block. And also, to make a suitable EV model using DC7 block. Objective: Run MATLAB demo ‘Speed control of a DC motor using BJT H-bridge’. Modify the model such that armature…

  Aim:         To study about the types of power converter circuits and to find out the EV steady state speed for an electric vehicle’s powertrain. Objective:  Which types of power converter circuits are employed in electric and hybrid electric vehicle?    An Electric…

Aim: To study about the powertrain block set which includes full EV reference and HEV reference applications. We will also be changing the parameters and also studying how the basic calculations are performed. Objective: What is the difference between mapped and dynamic model of engine, motor and generator? How can you…

Aim:        To study about the vehicle simulation using ADVISOR tool by providing extra load, changing the battery capacity and performing the gradeability test on a particular vehicle. Objective: For EV_defaults_in file, if cargo mass is 500 kg with all other default conditions, can the vehicle travel…

Aim : To solve the second order Ordinary Differential Equation using the example of simple pendulum that describes the position of the bob with respect to time using MATLAB. The program is computed to represent the motion of the pendulum with damping and also to simulate the motion of the pendulum. Governing Equations…

Aim : To plot the PV diagram for a Otto cycle using the engine kinematics and to calculate the thermal efficiency of the Otto cycle using MATLAB. Code : % Engine kinematics function [V] = engine_kinematics(bore,stroke,con_rod,cr,start_crank,end_crank) a = stroke/2 R = con_rod/a v_s = (pi/4)*bore^2*stroke; v_c = v_s/(cr-1);…

Aim:             To write a program in MATLAB which helps to optimise the stalagmite function and find the global maxima of the function. Objective:             To study the concept of genetic algorithm and stalagmite…

Aim:                 In this Project-2, ANSA pre-processor is used to generate mid surface, volume mesh. The quality criteria for some parts are different. Therefore, one should carefully apply them while meshing. Clear all off elements on surface…

Aim:        In this Project-1, ANSA pre-processor is used to generate mid surface using various options like casting, offset, middle, etc. Created 2D interpretation of the parent geometry. Extended mid surfaces in order to connect all the generated mid surfaces. Mesh the component using spot with given…

Aim:        To perform morphing techniques to the sheet metal component and mention the industrial uses of morphing. Procedure: The geometry is imported to ANSA and topo is performed in order to get a refined geometry. Then we must assign the element size in general, under perimeters title --->…

Aim:                 To obtain a 3D Tetra Mesh from the rear view mirror component and to check for geometrical errors and mesh with the given element Quality criteria. S.No  Quality Criteria  Value  1 Target/Average length  …

Aim:                 To check the given component for geometrical errors and mesh with the given element Quality criteria by extracting the mid-surface. The given element quality criteria is: S.No  Quality Criteria  Value  1 Target/Average…

Aim : To check for geometrical errors and mesh with the given element quality criteria for the given component. Procedure :  At first we must extract the .stp downloaded model to the ANSA workspace. Then we must assign the element size in general, under perimeters title ---> length ---> perimeters and macros as…

Aim:        To write a code in MATLAB to parse the NASA thermodynamic data file and calculate the thermodynamic properties of various gas species. Objective: To write a function that extracts the 14 co-efficients and calculates the specific heat, enthalpy and entropy for all the species in the data…

Aim: To implement the control logic of a ‘washing machine’ using Stateflow in a given sequence and to make Simulink chart for the ‘gear shift’ logic as per the given conditions. Objectives: Implement control logic of a “washing machine” using Stateflow as per given sequence:  If…

Aim: To make a Simulink model of doorbell using solenoid block. To make a Simulink model using a thermistor to sense the temperature of a heater and turn on and turn off the fan. Objectives: For the model of doorbell using solenoid block we have to create a situation where the switch is closed for 2 seconds and then released.…