Porras - Project Report Sample 2 PDF

ME273
Liquid Nitrogen Evaporation Unit

Gas Outlet
Liquid Nitrogen
Siphon Pump
10 Slots for 10 Peliter

Thermoelectric Elements
Liquid Nitrogen
Inlet
Extrusion Absorbs
Heat from Atmosphere
to Evaporate Liquid
Nitrogen
Isaac Porras
Mechanical and Aerospace Engineering Department
San Jose State University
December 14, 2005
Executive Summary
Research in alternative energy is essential to ensure that Americas dependence on
volatile oil supplies is reduced. A possible alternative energy source can be liquid
nitrogen. Liquid nitrogen is very cold and has a boiling temperature of -196 deg C. The
vapor produced from the evaporation of liquid nitrogen expands to 700 times its original
volume. This expansion can be used to push a piston and propel an air motor. Also, a
large amount of heat is required to evaporate liquid nitrogen into a vapor. This heat
energy can be converted into electricity through the use of peltier thermoelectric
elements. The heat needed to evaporate the liquid nitrogen will be supplied by the
surrounding atmospheric air, which will heat up a large surface area heat sink extrusion.
The peltier elements will be sandwiched between the liquid nitrogen evaporator and the
heat sink, which will create a temperature difference of 221 deg C and over 200 watts of
electrical energy. The electricity generated can be used to turn a DC electric motor. The
combination of air and electric motors can be used to power vehicles or other machines.
The prototype presented in this report is an evaporation unit required to turn liquid
nitrogen into gas.
The geometry is a relatively simple rectangular structure with dimensions 5.56in X
15in X 1in. The features were created by creating a 14.5in blind hole through the short
end of the rectangle. This hole is the inlet for the liquid nitrogen. Two more 2.78in blind
holes were created on the top of the structure. These holes will be used for the gas outlet
and liquid nitrogen pump. Also, ten 0.02in cavity slots were created on the surface of the
block for the ten peltier elements to fit in.
The Boundary conditions and load constraints of the model were 250 Psi on the inside,
a surface temperature of -196 deg C on the inside, a fixed screw hole in one corner with
free rotation, a heat load of 122.5 lbf*ft/sec on each peltier slot, an environment
temperature of 75 degrees, and three sides of the block were constrained with
displacement allowed in the direction of the plane. 3-D solid elements were used because
the model did not have a constant cross-sectional shape or symmetry.
The optimization of the structure was defined by maximizing the diameter of the
liquid nitrogen inlet 14.5in blind hole while keeping the safety factor under a value of
two. The larger the diameter of the hole became, the thinner the wall of the structure
becomes, which increased the stress of the structure. A large hole is desired in order to
maximize the flow of liquid nitrogen into the device. Also, a much larger pressure of
1000 Psi was applied to the inside of the structure and the same optimization described
above was calculated.
The results show that the device is very safe at 250 Psi with a safety factor of 24. The
optimization showed that with a bore hole diameter increased to 0.9in, the safety factor
decreased to 5. This showed that the device can support a much higher pressure load and
it was found that the model can withstand up to 1000 Psi and the maximum radius hole
size for the liquid to travel through was optimized to 0.328in. Also, the thermal stress
induced by the liquid nitrogen shank the entire block by 0.082in and the temperature
distribution throughout the structure varied by 0.3 deg F. The deflection due to thermal
contraction created an extremely high stress that could destroy the structure, thus the
screws used to mount the device must allow the structure to freely expand and contract
with changes in temperature.
Table of Contents
1. List of Tables ..4
2. List of Figures ..5-6
3. Project Objective ....7
4. Project Summary ...8-10
5. The Model Creation .11-26
6. Analysis and Results 27-30
7. Optimization Procedure ...31-36
8. Appendix .........37-67
List of Tables
1. Table 1. Model Data .. 8
2. Table 2. Results Summary for 250 Psi Load ..8
3. Table 3. Optimization Summary for 250 Psi Load .. ... ..9
4. Table 4. Results Summary for 1000 Psi Load ....9
5. Table 5. Optimization Summary for 1000 Psi Load ...9
6. Table 6. Results Summary for Thermal Analysis .....10
List of Figures
1. Figure 1. Concept of Generating Electricity by the Flow of Heat .7
2. Figure 2. Cut-Away View of the Liquid Nitrogen Evaporator ..7
3. Figure 3. Isometric View of the Liquid Nitrogen Evaporator ..11
4. Figure 4. Drawing of the Liquid Nitrogen Evaporator .11
5. Figure 5. First Extrusion of Model ...12
6. Figure 6. Second Extrusion of Model ...12
7. Figure 7. Third Extrusion of Model ..13
8. Figure 8. Fourth Extrusion of Model 13
9. Figure 9. Fifth Extrusion of Model ...14
10. Figure 10. Sixth Extrusion of Model ..14
11. Figure 11. Seventh Extrusion of Model ..15
12. Figure 12. Load for Model ......16
13. Figure 13. First Constraint for Model .....16
14. Figure 14. Second Constraint for Model ....17
15. Figure 15. Third Constraint for Model ...17
16. Figure 16. Material Selection for Model .18
17. Figure 17. Creating FEA of the Model .......18
18. Figure 18. Static FEA Settings ........19
19. Figure 19. Start Static FEA .19
20. Figure 20. Creating Thermal Analysis for Model ...20
21. Figure 21. Switching to Thermal Mode ......20
22. Figure 22. Selecting Thermal Heat Loads ..21
23. Figure 23. Selecting Temperature Boundary Conditions ...21
24. Figure 24. Creating a New Thermal Analysis File .....22
25. Figure 25. Configuring the Thermal Analysis 22
26. Figure 26. Start Thermal Analysis ......23
27. Figure 27. Creating the Thermal Stress Analysis ...23
28. Figure 28. Switching Back to Structure Mode .......24
29. Figure 29. Setting the Ambient Temperature .....24
30. Figure 30. Creating a New Thermal Stress Analysis File ..........25
31. Figure 31. Thermal Stress Analysis Settings ......25
32. Figure32. Start Thermal Stress Analysis ........26
33. Figure 33. FEA Displacement and Stress Fringe Plots ..........27
34. Figure 34. FEA Von Misses and Strain Energy vs. P-Loop Pass ...........28
35. Figure 35. Thermal Stress Displacement and Stress Fringe Plots ..28
36. Figure 36. Thermal Stress Analysis Mass and Strain Energy vs. P-Loop Pass ..29
37. Figure 37. Thermal Analysis Temperature Fringe Plot ..29
38. Figure 38. Creating Optimization ...... 31
39. Figure 39. Creating a Design Parameter .....32
40. Figure 40. Selecting a Design Parameter ........32
41. Figure 41. Creating a New Design Study File ....33
42. Figure 42. Opening the Design Study Parameter Window .....33
43. Figure 43. Creating the Design Study Parameters ..34
44. Figure 44. Start Design Study .....34
45. Figure 45. Optimization Mass and Stress vs. Pass Graph ...35
46. Figure 46. Optimized Model ...35
Project Objective
The objective of this project is to create a liquid nitrogen evaporator that will
withstand both a maximum pressure of 250 Psi and a temperature of -196 deg. C, and
with a size of 5.56in X 15in X 1in. This device will transform the heat used to evaporate
liquid nitrogen inside the aluminum block into electricity with the use of ten peltier
thermoelectric elements attached to the surface of the aluminum block, which turns heat
flow into electric energy (see below). The pressure created from this evaporation will
then be stored in an external tank and used to turn an air motor. This project will,
however, only focus on the device that will evaporate the liquid nitrogen up to 250 Psi.
The size of this evaporator is to be minimized in order to power a small vehicle like a go
kart or golf cart.
Figure 1. Concept of Generating Electricity by the Flow of Heat
Liquid Nitrogen
Siphon Pump
Gas Outlet
Liquid Nitrogen
Inlet
Figure 2. Cut-Away View of the Liquid Nitrogen Evaporator
7
Project Summary
Table 1. Model Data
Model Data
Model Type: (3-D, Plane Stress, Plane
Strain, or Axisymmetric)
Elements Type: (Beam, 2-D shell,
compressed shell, axisymmetric 1-D shell,
etc.)
Constraints: (where applied: surface ,
edge/curve, points; exact location, and
DOF that are fixed)
3-D
Load: (Type of load, where applied:

surface , edge/curve, points; exact location,
and magnitudes of load
250 Psi on the inside, a surface temperature

of -196 deg C on the inside, a heat load of
122.5 lbf*ft/sec on each peltier slot, an
environment temperature of 75 degrees,
Solid
A fixed screw hole in one corner with free

rotation, three sides of the block were
constrained with displacement allowed in
the direction of the plane.
Material Properties
Aluminum 6061
Yield Strength = 37kPsi
Density
0.0002536 [lbf sec^2 / in^4]
Young's Modulus
1e+07 [lbf / in^2]
Poisson's Ratio
0.3
Conductivity
22.49 [lbf / (sec F)]
Specific Heat
829900 [in^2 / (sec^2 F)]
Thermal Expansion 1.3e-05 [/ F]

Shear Stiffness
Units used
3.84615e+06 [lbf / in^2]
IPS
Table 2. Results Summary for 250 Psi Load
Results Summary for 250 Psi Load

Maximum static stress:
Yield Strength of the material:
Maximum deflection in the model:
Factor of safety
Total number of elements used and their
types:
Total CPU run time:
1.5 kPsi
37 kPsi
0.000029in
24
5190 Solid Elements
1623.51 sec
Using the 3-D solid elements took a very ling time and the school computers were
not powerful enough to compute the FEA. After, using a more powerful
computer, no problems were encountered in the FEA.
Table 3. Optimization Summary for 250 Psi Load
Optimization Summary for 250 Psi Load

Optimized Parameters:
Liquid Nitrogen Inlet Hole Diameter

Min: 0.25in
Max: 0.45in
Minimize Von Misses Stress
Von Misses Stress < 19500 Psi
= Safety Factor of 1.9 or more
The original radius was 0.25in. The
optimal radius was found to be the
maximum 0.45in radius with a safety factor
of 5.
815.5 sec
Optimization Goal:
Limits:
A Comparison of the New and Optimized
Parameters:
Total CPU run time:
Table 4. Results Summary for 1000 Psi Load
Results Summary for 1000 Psi Load

Maximum static stress:
Factor of safety
types:
Total CPU run time:
6.02 kPsi
37 kPsi
0.000029in
6
5190 Solid Elements
1629.03 sec
Using the 3-D solid elements took a very ling time and the school computers were
not powerful enough to compute the FEA. After, using a more powerful
computer, no problems were encountered in the FEA.
Table 5. Optimization Summary for 1000 Psi Load
Optimization Summary for 1000 Psi Load

Optimized Parameters:
Liquid Nitrogen Inlet Hole Diameter

Min: 0.25in
Max: 0.45in
Minimize Von Misses Stress
Von Misses Stress < 19500 Psi
For a Safety Factor of 1.9 or more
The original radius was 0.25in. The
optimal radius was found to be the
maximum 0.328in radius with a safety
factor of 1.9.
4667.81 sec
Optimization Goal:
Limits:
A Comparison of the New and Optimized
Parameters:
Total CPU run time:
Table 6. Results Summary for Thermal Analysis
Results Summary for Thermal Analysis

Temperature Distribution:
Factor of safety
types:
Total CPU run time:
Min: -320.46 deg F

Max: -320.80 deg F
37 kPsi
0.082in
5
5190 Solid Elements
1629.03 sec
10
The Model Creation

Pro/E:
Figure 3. Isometric View of the Liquid Nitrogen Evaporator
Figure 4. Drawing of the Liquid Nitrogen Evaporator

The model is very straightforward to create. Start with a rectangular block with the
overall dimension shown above. Then create the holes and recess cut-outs in the locations
shown in the print. Use Aluminum 6061 material for the model. The following figures are
11
screen shots of the extrusion steps for creating the model. Make sure IPS units is selected.
Please refer to drawing Figure 4 in previous page for detailed dimensions:
1) Extrude the solid rectangle with overall dimensions 5.56 X 15 X 1
Figure 5. First Extrusion of Model

2) Extrude cut the Liquid Nitrogen inlet blind hole.
Figure 6. Second Extrusion of Model
12
3) Extrude cut both gas and pump holes.
Figure 7. Third Extrusion of Model

4) Extrude cut the peltier thermoelectric element recess.
Figure 8. Fourth Extrusion of Model
13
5) Right-click the previous extrusion in the Tree window and select the pattern command
to create two rows of five recesses.
Figure 9. Fifth Extrusion of Model

6) Extrude cut the mounting hole in one corner.
Figure 10. Sixth Extrusion of Model
14
7) Right-click the previous extrusion in the Tree window and select the pattern command
to create two rows of three holes. The model is complete.
Figure 11. Seventh Extrusion of Model

Pro/M:
The model type used is 3-D solid elements. 3-D elements were used because there was
no constant cross-sectional geometry and there was no symmetry. No idealizations were
used in this model. The two magnitudes of the loads used were pressure loads of 250 Psi
and 1000 Psi. The 1000 Psi load will be used in the following Pro/M procedure
explanation. Steps for creating the loads, constraints, materials, thermal constraints, and
analysis will be discussed in the following figures:
15
1) Click on the New Pressure Load button, hold the Cntrl key and select the red areas
inside model. Release the Cntrl key and click the middle mouse button. Then type a value
of 1000 Psi and click Ok.
Figure 12. Load for Model

2) Click on the New Displacement Constraint button, hold the Cntrl key and select the
10 red areas where the peltier recesses are. Release the Cntrl key and click the middle
mouse button. Then set the X and Y translation to Free and click ok.
Figure 13. First Constraint for Model
16
red area on the front side of the structure. Release the Cntrl key and click the middle
mouse button. Then set the Y and Z translation to Free and click ok.
Figure 14. Second Constraint for Model

bottom of the structure. Release the Cntrl key and click the middle mouse button. Then
set the X and Z translation to Free and click ok.
Figure 15. Third Constraint for Model
17
4) Click on the Define Material button and click on AL6061. Press the >>> button
and click the Assign button. Select the Part selection and click on the structure. Then
click the Close button.
Figure 16. Material Selection for Model

5) Click on the Analysis and Design Studies button, click the File menu button, and
then select the New Static menu item.
Figure 17. Creating FEA of the Model
18
6) Select the Multi-Pass Adaptive selection in the Method menu, then change the
maximum polynomial order to 9 and click Ok.
Figure 18. Static FEA Settings

7) Click Start Run button and wait for the FEA to complete.
Figure 19. Start Static FEA
19
8) After the FEA is complete, the thermal loads and constraints can be added. Click on
Edit in the menu and select Mechanica Model Type.
Figure 20. Creating Thermal Analysis for Model

9) Change the Mode to Thermal and click Ok.
Figure 21. Switching to Thermal Mode
20
10) Select the New Heat Load on Surface button, hold down the Cntrl key and select
the 10 red shaded areas where the 10 peltier element recesses are. Release the Cntrl
button and click the middle mouse button. Then type 122.5 lbf*ft/sec in the Q section and
click Ok.
Figure 22. Selecting Thermal Heat Loads

11) Click the New Prescribed Temperature button, hold down the Cntrl key and select
the red shaded areas on the inside of the structure. Release the Cntrl key and click the
middle mouse button. Then type -321.8 deg F in the temperature section to simulate the
liquid nitrogen inside the structure and click Ok.
Figure 23. Selecting Temperature Boundary Conditions

21
12) Click on the Analysis and Design Studies button, click File from the menu, and
select the New Steady State Thermal menu item.
Figure 24. Creating a New Thermal Analysis File

Figure 25. Configuring the Thermal Analysis
22
14) Click Start Run button and wait for the thermal analysis to complete.
Figure 26. Start Thermal Analysis

15) Once the thermal analysis is complete, the thermal stress analysis can begin. Click
Edit button in the menu and select Mechanical Model Type.
Figure 27. Creating the Thermal Stress Analysis
23
16) Select Structure from the Mode section and click Ok.
Figure 28. Switching Back to Structure Mode

17) Click Insert from the Menu, select the MECT/T menu item, type 75 deg F in the
Reference Temperature section to simulate ambient air temperature, and click Ok.
Figure 29. Setting the Ambient Temperature
24
18) Click on the Analysis and Design Studies button, click File from the menu, and
select the New Static menu item.
Figure 30. Creating a New Thermal Stress Analysis File

Figure 31. Thermal Stress Analysis Settings

25
20) Click Start Run button and wait for the thermal FEA to complete.
Figure32. Start Thermal Stress Analysis
26
Analysis and Results

Static:
max_disp_mag:
max_stress_vm:
1.162636e-04
6.019675e+03
0.3%
0.2%
Thermal:
max_disp_mag:
max_stress_vm:
max_temperature:
min_temperature:
8.242551e-02
0.0%
6.596068e+03
0.0%
-3.204613e+02
0.0%
-3.208000e+02
0.0%
(See Appendix for Complete Analysis RPT Results)
Figure 33. FEA Displacement and Stress Fringe Plots
27
Figure 34. FEA Von Misses and Strain Energy vs. P-Loop Pass
Figure 35. Thermal Stress Displacement and Stress Fringe Plots

28
Figure 36. Thermal Stress Analysis Mass and Strain Energy vs. P-Loop Pass
Figure 37. Thermal Analysis Temperature Fringe Plot

29
The results showed that the most stress is created by the thermal stress and not by the
pressure load. The results took over a day to complete the analysis because 3-D solid
elements were used and over 5000 elements were used. Also, the thermal analysis
showed that the temperature variation is relatively constant throughout the structure even
though the liquid nitrogen only touches the inside surface of the inlet center hole and with
nearly 3000 watts of total heat flow through the surface of the peltier recesses.
The analysis showed that the objectives of this project were met and exceeded. The
structure withstood over four times the original required load with a safety factor greater
than two. However, because of the large contraction deflection of the structure due the
extremely cold temperatures in the center of the structure, the structure must be allowed
to expand and contract freely or else the structure will be destroyed. The results of the
analysis seemed to be very realistic and accurate. Real-life testing of this design can be
used to verify the results.
30
Optimization Procedure
The design parameters for the optimization was to maximize the diameter of the liquid
nitrogen inlet blind hole in order to allow the maximum amount of liquid nitrogen to flow
into the structure while keeping the safety factor greater or equal to 1.9. Steps for
completing the optimization will be shown in the following figures:
1) Select Analysis from the menu and select the Mechanica Design Controls menu
item.
Figure 38. Creating Optimization
31
2) Select Design Params from the menu and click the Create button.
Figure 39. Creating a Design Parameter

3) Select the 0.25 radius dimension and click the middle mouse button. Then click
Done/Return from the menu.
Figure 40. Selecting a Design Parameter
32
4) Click the Analysis and Design Studies button, click File from the menu, and select
the New Design Study menu item.
Figure 41. Creating a New Design Study File

5) Select Optimization from the Type menu.
Figure 42. Opening the Design Study Parameter Window
33
6) Check the Goal section, click Select, choose max_stress_vm from the menu and
click Ok. Then check the Limits On section and click Create, select
max_stress_vm from the menu and click Ok. Select the > sign and type 19500 Psi
in the limit sub-window. Then check the item in the Parameter window, select
Minimum in the Min section, Maximum in the Init section, and Maximum in the
Max section. Lastly, uncheck the Repeat P-Loop Convergence and click Accept.
Figure 43. Creating the Design Study Parameters

7) Click Start Run button and wait for the thermal analysis to complete.
Figure 44. Start Design Study

34
The following figures are the results of the optimization:
Figure 45. Optimization Mass and Stress vs. Pass Graph
Figure 46. Optimized Model

35
A large hole is desired to maximize the flow of liquid nitrogen into the liquid nitrogen
evaporator. However, if the size of the hole is too large, then the wall thickness of the
structure will decrease, which will increase the stress and possibly destroy the structure
with a 1000 Psi load. The optimization began with a maximum an initial radius of 0.45in.
The computer then decreased the radius of the liquid nitrogen inlet blind hole until the
safety factor reached a value of more than 1.9. As the radius decreased, the mass
increased and the stress decreased. There was some trouble with the optimization,
because the optimized radius of 0.328 was found after the first run. After the first run, the
optimization produced an error and crashed. The optimization did not successfully
complete, but before the optimization crashed, the data was saved. The incomplete RPT
file showed that the final optimized radius was the correct value because the Von Misses
stress calculated at the optimized diameter made a safety factor of 1.92, which is only
slightly higher that 1.9. Thus, the optimization RPT data is still useful information, even
though the value was found after the first run and crashed.
36
Appendix
a. Project Proposal
b. Project Research
f. Edited *.rpt files
37
Liquid Nitrogen Evaporation Unit
Team Member:
Isaac Porras
11/3/05
38
Objective:
The objective of this project is to create a liquid nitrogen evaporator that will
withstand both a maximum pressure of 300 psi and a temperature of -196 deg. C, and
with a size of about 5in X 5in X 1in. This device will be used to generate electricity with
the use of peltier elements (see figure below), which turn heat flow into electric energy.
The pressure created from this evaporation will then be used to turn an air motor. This
project will, however, only focus on the device that will evaporate the liquid nitrogen up
to 300 psi. The size of this evaporator is to be minimized in order to power a small
vehicle like a go kart or golf cart.
Figure 1. Concept of Generating Electricity by the Flow of Heat
(See Detailed Design Sketch on Next Page)
39
Procedure:
The procedure to complete this project is to first model an aluminum block with
the appropriate holes for liquid nitrogen to travel, mounting holes, a groove to fit a peltier
device, holes for liquid nitrogen level sensors, and holes for temperature sensors. 3-D
elements will then be used to analyze the 300psi pressure and -196 deg. C temperature
inside the vessel. Then the safety factor will be calculated and the device will be
optimized to minimize mass. A heat-sink will then be attached to the bottom of the
evaporator increase the heat-flow into the evaporator.
End Product Deliverables:
A liquid nitrogen evaporator that has:
1. Minimized mass
2. Safety factor 2
3. Ability to mount two peltier elements
4. Ability to mount to a heat-sink to increase heat flow into the evaporator
5. Ability to mount temperature sensors
6. Ability to mount liquid nitrogen level sensors
7. Ability to mount Pressure sensors
8. Ability to withstand Thermal Stress
Timetable:
October 24 through December 12
Week/Task
1. Prepare Proposal
2. Initial Design
3. Part FEA analysis
4. Part Optimization
5. Assembly
6. Drawings
7. Analysis
8. Final Report
Oct
24
40
31
Nov
7
14
21
28
Dec
5
12
41
-----------------------------------------------------------Mechanica Structure Version K-01-27:spg

Summary for Design Study "psi1000_static"
Sat Dec 10, 2005 23:35:53
-----------------------------------------------------------Run Settings
Memory allocation for block solver: 1000.0
Parallel Processing Status
Parallel task limit for current run:
2
Parallel task limit for current platform:
64
Number of processors detected automatically: 2
Checking the model before creating elements...
These checks take into account the fact that AutoGEM will
automatically create elements in volumes with material
properties, on surfaces with shell properties, and on curves
with beam section properties.
Generate elements automatically.
Checking the model after creating elements...
No errors were found in the model.
Mechanica Structure Model Summary
Principal System of Units: Inch Pound Second (IPS)
Length:
in
Force:
lbf
Time:
sec
Temperature: F
Model Type: Three Dimensional
Points:
Edges:
Faces:
1762
8559
11980
Springs:
Masses:
Beams:
Shells:
Solids:
0
0
0
0
5190
Elements:
5190
42
-----------------------------------------------------------Standard Design Study

Static Analysis "psi1000_static":
Convergence Method: Multiple-Pass Adaptive
Plotting Grid:
4
Convergence Loop Log:
(23:36:05)
>> Pass 1 <<

Calculating Element Equations
(23:36:06)
Total Number of Equations: 4737
Maximum Edge Order:
1
Solving Equations
(23:36:07)
Post-Processing Solution
(23:36:08)
Calculating Disp and Stress Results (23:36:08)
Checking Convergence
(23:36:44)
Elements Not Converged:
5190
Edges Not Converged:
8559
Local Disp/Energy Index: 100.0%
Global RMS Stress Index: 100.0%
Resource Check
(23:36:44)
Elapsed Time (sec):
51.18
CPU Time
(sec):
18.95
Memory Usage
(kb): 1082174
Wrk Dir Dsk Usage (kb):
40960
>> Pass 7 <<
(23:50:12)
Maximum Edge Order:
8
Solving Equations
(23:51:43)
(23:59:17)
(00:01:10)
0
0
Local Disp/Energy Index:
7.0%
Global RMS Stress Index:
5.4%
RMS Stress Error Estimates:
Load Set
Stress Error % of Max Prin Str
43
---------------- ------------ ----------------LoadSet1

1.36e+02
1.8% of 7.34e+03
Resource Check
(00:02:15)
Elapsed Time (sec): 1581.95
CPU Time
(sec): 1628.16
Memory Usage
(kb): 1216297
Wrk Dir Dsk Usage (kb): 2634752
The analysis converged to within 10% on
edge displacement, element strain energy,
and global RMS stress.
Total Mass of Model: 2.000164e-02
Total Cost of Model: 0.000000e+00
Constraint Set: ConstraintSet1
Load Set: LoadSet1
Resultant Load on Model:
in global X direction: 4.148195e-03
in global Y direction: -3.927022e+02
in global Z direction: -2.804163e-02
Measures:
Name
Value Convergence
-------------- ------------- ----------max_beam_bending: 0.000000e+00
0.0%
max_beam_tensile: 0.000000e+00
0.0%
max_beam_torsion: 0.000000e+00
0.0%
max_beam_total: 0.000000e+00
0.0%
max_disp_mag:
1.162636e-04
0.3%
max_disp_x:
4.990149e-05
0.3%
max_disp_y:
5.065681e-05
0.6%
max_disp_z:
-1.149555e-04
0.4%
max_prin_mag:
-7.341313e+03 14.8%
max_rot_mag:
0.000000e+00
0.0%
max_rot_x:
0.000000e+00
0.0%
max_rot_y:
0.000000e+00
0.0%
max_rot_z:
0.000000e+00
0.0%
max_stress_prin: 5.903367e+03 10.1%
max_stress_vm:
6.019675e+03
0.2%
max_stress_xx: -2.443959e+03 12.3%
44
max_stress_xy:
max_stress_xz:
max_stress_yy:
max_stress_yz:
max_stress_zz:
min_stress_prin:
strain_energy:
9.118155e+02
8.6%
-3.144181e+03 13.1%
-2.978996e+03 13.4%
-2.714660e+03 15.7%
-6.207449e+03 11.1%
-7.341313e+03 14.8%
6.773170e-01
0.2%
Analysis "psi1000_static" Completed (00:02:17)

-----------------------------------------------------------Memory and Disk Usage:
Machine Type: Windows NT/x86
RAM Allocation for Solver (megabytes): 1000.0
Total Elapsed Time (seconds): 1585.01
Total CPU Time (seconds): 1629.03
Maximum Memory Usage (kilobytes): 1216297
Working Directory Disk Usage (kilobytes): 2634752
Results Directory Size (kilobytes):
81676 .\psi1000_static
Maximum Data Base Working File Sizes (kilobytes):
1048576 .\psi1000_static.tmp\kblk1.bas
832512 .\psi1000_static.tmp\kblk2.bas
668672 .\psi1000_static.tmp\kel1.bas
84992 .\psi1000_static.tmp\oel1.bas
-----------------------------------------------------------Run Completed
Sun Dec 11, 2005 00:02:18
45
-----------------------------------------------------------Mechanica Thermal Version K-01-27:spg

Summary for Design Study "me273_project_thermal"
Sat Dec 10, 2005 16:24:56
-----------------------------------------------------------Run Settings
2
64
Mechanica Thermal Model Summary
Length:
in
Force:
lbf
Time:
sec
Temperature: F
Points:
Edges:
Faces:
1762
8559
11980
Beams:
Shells:
Solids:
0
0
5190
Elements:
5190
------------------------------------------------------------
46
Standard Design Study

Steady-State Thermal Analysis "me273_project_thermal":
Plotting Grid:
4
(16:25:08)
>> Pass 1 <<

(16:25:08)
Maximum Edge Order:
1
Solving Equations
(16:25:09)
(16:25:09)
Calculating Temp and Flux Results
(16:25:09)
(16:25:13)
5190
8559
Local Temp/Energy Index: 100.0%
Global Energy Index:
100.0%
Resource Check
(16:25:13)
Elapsed Time (sec):
16.80
CPU Time
(sec):
14.83
Memory Usage
(kb): 1083884
20480
>> Pass 2 <<
(16:25:13)
Maximum Edge Order:
2
Solving Equations
(16:25:15)
(16:25:16)
(16:25:16)
(16:25:20)
2912
0
52.5%
Resource Check
(16:25:21)
Elapsed Time (sec):
25.02
CPU Time
(sec):
21.08
Memory Usage
(kb): 1088300
20480
47
>> Pass 3 <<

(16:25:21)
Maximum Edge Order:
3
Solving Equations
(16:25:23)
(16:25:26)
(16:25:26)
(16:25:31)
1233
0
10.4%
Resource Check
(16:25:32)
Elapsed Time (sec):
35.43
CPU Time
(sec):
30.13
Memory Usage
(kb): 1097734
20480
>> Pass 4 <<
(16:25:32)
Maximum Edge Order:
4
Solving Equations
(16:25:37)
(16:25:41)
(16:25:41)
(16:25:46)
163
0
5.7%
Resource Check
(16:25:47)
Elapsed Time (sec):
51.20
CPU Time
(sec):
44.89
Memory Usage
(kb): 1125676
29696
>> Pass 5 <<
(16:25:48)
Maximum Edge Order:
5
Solving Equations
(16:25:52)
(16:25:57)
(16:25:57)
(16:26:03)
2
0
48
Local Temp/Energy Index:

8.1%
3.3%
Resource Check
(16:26:04)
Elapsed Time (sec):
67.79
CPU Time
(sec):
60.42
Memory Usage
(kb): 1134205
34816
>> Pass 6 <<
(16:26:04)
Maximum Edge Order:
6
Solving Equations
(16:26:08)
(16:26:12)
(16:26:13)
(16:26:19)
0
0
Local Temp/Energy Index:
4.5%
0.8%
RMS Flux Error Estimates:
Load Set
Flux Error % of Max Flux
---------------- ------------ ----------------ThermLoadSet2
2.45e+00
5.3% of 4.62e+01
Resource Check
(16:26:24)
Elapsed Time (sec):
87.39
CPU Time
(sec):
76.77
Memory Usage
(kb): 1134205
34816
edge temperature and element energy norms.
Constraint Set: BndryCondSet2
Load Set: ThermLoadSet2
Measures:
49
Name
Value Convergence
-------------- ------------- ----------energy_norm:
1.434345e+01
0.0%
max_flux_mag:
4.615338e+01
1.4%
max_flux_x:
-2.400180e+01
0.5%
max_flux_y:
-3.243341e+01
0.0%
max_flux_z:
2.531674e+01
1.2%
max_grad_mag:
2.052174e+00
1.4%
max_grad_x:
1.067221e+00
0.5%
max_grad_y:
1.442126e+00
0.0%
max_grad_z:
-1.125689e+00
1.2%
max_temperature: -3.204613e+02
0.0%
min_temperature: -3.208000e+02
0.0%
Analysis "me273_project_thermal" Completed (16:26:25)
43454 .\me273_project_thermal
34816 .\me273_project_thermal.tmp\kel1.bas
-----------------------------------------------------------Run Completed
Sat Dec 10, 2005 16:26:25
50

Mechanica Thermal Version K-01-27:spg
Summary for Design Study "Trial1"
Sat Dec 10, 2005 18:23:05
-----------------------------------------------------------Run Settings
2
64
Length:
in
Force:
lbf
Time:
sec
Temperature: F
Points:
Edges:
Faces:
1762
8559
11980
Springs:
Masses:
Beams:
Shells:
Solids:
0
0
0
0
5190
51
Elements:
5190
-----------------------------------------------------------Mechanica Thermal Model Summary

Length:
in
Force:
lbf
Time:
sec
Temperature: F
Points:
Edges:
Faces:
1762
8559
11980
Beams:
Shells:
Solids:
0
0
5190
Elements:
5190

Analyses:
Trial1
me273_project_thermal
Analysis Trial1 requires input data from
analysis me273_project_thermal.
Static Analysis "Trial1":
Plotting Grid:
4
(18:24:39)
>> Pass 1 <<

(18:24:40)
52
Maximum Edge Order:

1
Solving Equations
(18:24:44)
(18:24:45)
(18:25:33)
5190
8559
Resource Check
(18:25:34)
CPU Time
(sec):
95.28
Memory Usage
(kb): 1134269
40960
>> Pass 4 <<
(18:27:33)
Maximum Edge Order:
4
Solving Equations
(18:27:37)
(18:27:39)
(18:28:28)
0
0
0.0%
0.2%
Load Set
---------------- ------------ ----------------LoadSet1
7.68e+02
12.7% of 6.03e+03
Resource Check
(18:28:38)
CPU Time
(sec): 169.06
Memory Usage
(kb): 1164631
43008
53

Load Set: LoadSet1
Measures:
Name
Value Convergence
0.0%
0.0%
0.0%
0.0%
max_disp_mag:
8.242551e-02
0.0%
max_disp_x:
-7.715425e-02
0.0%
max_disp_y:
-2.860447e-02
0.0%
max_disp_z:
5.050752e-03
0.0%
max_prin_mag:
-6.025085e+03
0.0%
max_rot_mag:
0.000000e+00
0.0%
max_rot_x:
0.000000e+00
0.0%
max_rot_y:
0.000000e+00
0.0%
max_rot_z:
0.000000e+00
0.0%
max_stress_prin: 4.387434e+03
0.0%
max_stress_vm:
6.596068e+03
0.0%
max_stress_xx: -5.548722e+03
0.0%
max_stress_xy:
2.199788e+03
0.0%
max_stress_xz: -1.611881e+03
0.0%
max_stress_yy: -4.827445e+03
0.0%
max_stress_yz: -1.935812e+03
0.0%
max_stress_zz:
2.948472e+03
0.0%
min_stress_prin: -6.025085e+03
0.0%
strain_energy:
3.502546e-01
0.0%
Analysis "Trial1" Completed (18:28:40)
54

85845 .\Trial1
22528 .\Trial1.tmp\kel1.bas
20480 .\Trial1.tmp\oel1.bas
-----------------------------------------------------------Run Completed
Sat Dec 10, 2005 18:28:40
55

Summary for Design Study "psi1000_optimization"
Sun Dec 11, 2005 12:18:02
-----------------------------------------------------------Run Settings
Perform mesh smoothing after each parameter update.
Remesh after each parameter update.
2
64
Length:
in
Force:
lbf
Time:
sec
Temperature: F
Points:
Edges:
Faces:
1762
8559
11980
Springs:
Masses:
Beams:
Shells:
Solids:
0
0
0
0
5190
56
Elements:
5190
-----------------------------------------------------------Optimization Design Study

Using Gradient Projection Optimization Algorithm
Sun Dec 11, 2005 12:18:09
Goal
Analysis: psi1000_static
Load Set: LoadSet1
Minimize: max_stress_vm
Limit: 1
Analysis: psi1000_static
Load Set: LoadSet1
max_stress_vm < 1.9500e+004
Parameter
d8
Min. Value Initial Value Max. Value

0.25
0.45
0.45
Optimization Convergence Tolerance: 1

%
Maximum Number of Optimization Iterations: 20
Begin Analysis of Goal and Limits of
(12:18:09)
Initial Design
** Warning: Analysis did not converge during optimization
because max polynomial order of 9 was reached.
24.5%
11.0%
-----------------------------------------------------------Initial Design Status

Parameters:
d8
0.45
Status of Optimization Limits:
1. max_stress_vm 4.9694e+04 < 1.9500e+04 (VIOLATED)
The initial design violates the optimization limits.
Begin search for feasible values of
parameters.
(13:21:30)
57
Begin Optimization Iteration 1
(13:21:30)
Initial Goal: 4.9694e+04

Fixing Optimization Limit
1 (max_stress_vm)
(13:21:30)
Parameters:
d8
0.360707
Status of Optimization Limit: 1
max_stress_vm 2.4484e+04 < 1.9500e+04 (VIOLATED)
Parameters:
d8
0.328472
Status of Optimization Limit: 1
max_stress_vm 1.9196e+04 < 1.9500e+04 (satisfied)
1. max_stress_vm 1.9196e+04 < 1.9500e+04 (satisfied)
The parameter values are now feasible.
Result of Optimization Iteration 1
Parameters:
d8
0.328472
Goal: 1.9196e+04
Resource Check
(14:29:12)
CPU Time
(sec): 4667.81
Memory Usage
(kb): 1394744
(14:29:12)
Begin Line Search

(14:29:13)
Step size governed by lower limit on
parameter d8
Line Search Iteration 1
Parameters:
d8
0.324548
58
Goal: 1.9056e+04
Parameters:
d8
0.322331
Goal: 1.8941e+04
Parameters:
d8
0.25
Goal: 1.5271e+04
** Warning: Changing the parameters has produced invalid
model or geometry for the following parameter
values:
Parameters:
d8
0.252
Recovering from invalid parameter values by cutting
step size.
59

Summary for Design Study "me273_project_static"
Sat Dec 10, 2005 15:50:57
-----------------------------------------------------------Run Settings
2
64
Length:
in
Force:
lbf
Time:
sec
Temperature: F
Points:
Edges:
Faces:
1762
8559
11980
Springs:
Masses:
Beams:
Shells:
Solids:
0
0
0
0
5190
Elements:
5190
60

Static Analysis "me273_project_static":
Plotting Grid:
4
(15:51:10)
>> Pass 1 <<

(15:51:11)
Maximum Edge Order:
1
Solving Equations
(15:51:14)
(15:51:15)
(15:51:54)
5190
8559
Resource Check
(15:51:54)
Elapsed Time (sec):
57.17
CPU Time
(sec):
19.02
Memory Usage
(kb): 1083126
40960
>> Pass 7 <<
(16:05:21)
Maximum Edge Order:
8
Solving Equations
(16:06:54)
(16:14:40)
(16:16:29)
0
0
7.0%
5.4%
Load Set
61
---------------- ------------ ----------------LoadSet1

3.39e+01
1.8% of 1.84e+03
Resource Check
(16:17:30)
CPU Time
(sec): 1622.59
Memory Usage
(kb): 1217001
Load Set: LoadSet1
Measures:
Name
Value Convergence
0.0%
0.0%
0.0%
0.0%
max_disp_mag:
2.906589e-05
0.3%
max_disp_x:
1.247537e-05
0.3%
max_disp_y:
1.266420e-05
0.6%
max_disp_z:
-2.873888e-05
0.4%
max_prin_mag:
-1.835328e+03 14.8%
max_rot_mag:
0.000000e+00
0.0%
max_rot_x:
0.000000e+00
0.0%
max_rot_y:
0.000000e+00
0.0%
max_rot_z:
0.000000e+00
0.0%
max_stress_prin: 1.475842e+03 10.1%
max_stress_vm:
1.504919e+03
0.2%
max_stress_xx: -6.109898e+02 12.3%
62
max_stress_xy:
max_stress_xz:
max_stress_yy:
max_stress_yz:
max_stress_zz:
min_stress_prin:
strain_energy:
2.279539e+02
8.6%
-7.860452e+02 13.1%
-7.447491e+02 13.4%
-6.786650e+02 15.7%
-1.551862e+03 11.1%
-1.835328e+03 14.8%
4.233231e-02
0.2%
Analysis "me273_project_static" Completed (16:17:33)

81652 .\me273_project_static
1048576 .\me273_project_static.tmp\kblk1.bas
832512 .\me273_project_static.tmp\kblk2.bas
668672 .\me273_project_static.tmp\kel1.bas
84992 .\me273_project_static.tmp\oel1.bas
-----------------------------------------------------------Run Completed
Sat Dec 10, 2005 16:17:34
63

Mechanica Thermal Version K-01-27:spg
Summary for Design Study "optimization"
Sat Dec 10, 2005 20:29:18
-----------------------------------------------------------Run Settings
Perform mesh smoothing after each parameter update.
Remesh after each parameter update.
2
64
Length:
in
Force:
lbf
Time:
sec
Temperature: F
Points:
Edges:
Faces:
1762
8559
11980
Springs:
Masses:
Beams:
Shells:
0
0
0
0
64
Solids:
5190
Elements:
5190
-----------------------------------------------------------Mechanica Thermal Model Summary

Length:
in
Force:
lbf
Time:
sec
Temperature: F
Points:
Edges:
Faces:
1762
8559
11980
Beams:
Shells:
Solids:
0
0
5190
Elements:
5190
-----------------------------------------------------------Optimization Design Study

Using Gradient Projection Optimization Algorithm
Sat Dec 10, 2005 20:29:25
Goal
Analysis: me273_project_static
Load Set: LoadSet1
Minimize: max_stress_vm
Limit: 1
Analysis: me273_project_static
Load Set: LoadSet1
max_stress_vm < 1.9500e+004
Parameter
d8
Min. Value Initial Value Max. Value

0.25
0.45
0.45
65
Optimization Convergence Tolerance: 1

%
Maximum Number of Optimization Iterations: 20
Begin Analysis of Goal and Limits of
(20:29:25)
Initial Design
** Warning: Analysis did not converge during optimization
because max polynomial order of 9 was reached.
11.9%
0.3%
-----------------------------------------------------------Initial Design Status

Parameters:
d8
0.45
Goal (before optimization): 6.6134e+03
Resource Check
(20:44:37)
CPU Time
(sec): 666.62
Memory Usage
(kb): 1432870
(20:44:37)
Optimization converged on limit boundary.

Best Design Found:
Parameters:
d8
0.45
Goal: 6.6134e+03
Optimization study statistics:
Number of Base Analyses: 5
Number of Perturbation Analyses: 2
66

Total Elapsed Time in Parameter Updates (seconds):
122.23
Total Engine Elapsed Time Minus Param. Updates (seconds):
1053.51
Total CPU Time in Parameter Updates (seconds):
57.80
Total Engine CPU Time Minus Param. Updates (seconds):
815.50
118127 .\optimization
192512 .\optimization.tmp\kel1.bas
40960 .\optimization.tmp\oel1.bas
-----------------------------------------------------------Run Completed
Sat Dec 10, 2005 20:48:53
67

Porras - Project Report Sample 2 PDF

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ME273

Liquid Nitrogen Evaporation Unit

10 Slots for 10 Peliter

Figure 1. Concept of Generating Electricity by the Flow of Heat

Load: (Type of load, where applied:

250 Psi on the inside, a surface temperature

A fixed screw hole in one corner with free

0.0002536 [lbf sec^2 / in^4]

1e+07 [lbf / in^2]

22.49 [lbf / (sec F)]

829900 [in^2 / (sec^2 F)]

Thermal Expansion 1.3e-05 [/ F]

3.84615e+06 [lbf / in^2]

Results Summary for 250 Psi Load

Table 3. Optimization Summary for 250 Psi Load

Optimization Summary for 250 Psi Load

Liquid Nitrogen Inlet Hole Diameter

Total CPU run time:

Table 4. Results Summary for 1000 Psi Load

Results Summary for 1000 Psi Load

Optimization Summary for 1000 Psi Load

Liquid Nitrogen Inlet Hole Diameter

Total CPU run time:

Table 6. Results Summary for Thermal Analysis

Results Summary for Thermal Analysis

Min: -320.46 deg F

The Model Creation

Figure 3. Isometric View of the Liquid Nitrogen Evaporator

Figure 4. Drawing of the Liquid Nitrogen Evaporator

Figure 5. First Extrusion of Model

Figure 6. Second Extrusion of Model

3) Extrude cut both gas and pump holes.

Figure 7. Third Extrusion of Model

Figure 8. Fourth Extrusion of Model

Figure 9. Fifth Extrusion of Model

Figure 10. Sixth Extrusion of Model

Figure 11. Seventh Extrusion of Model

Figure 12. Load for Model

Figure 13. First Constraint for Model

Figure 14. Second Constraint for Model

Figure 15. Third Constraint for Model

Figure 16. Material Selection for Model

Figure 17. Creating FEA of the Model

Figure 18. Static FEA Settings

Figure 19. Start Static FEA

Figure 20. Creating Thermal Analysis for Model

Figure 21. Switching to Thermal Mode

Figure 22. Selecting Thermal Heat Loads

Figure 23. Selecting Temperature Boundary Conditions

Figure 24. Creating a New Thermal Analysis File

Figure 25. Configuring the Thermal Analysis

Figure 26. Start Thermal Analysis

Figure 27. Creating the Thermal Stress Analysis

Figure 28. Switching Back to Structure Mode

Figure 29. Setting the Ambient Temperature

Figure 30. Creating a New Thermal Stress Analysis File

Figure 31. Thermal Stress Analysis Settings

Figure32. Start Thermal Stress Analysis

Analysis and Results

(See Appendix for Complete Analysis RPT Results)

Figure 33. FEA Displacement and Stress Fringe Plots

Figure 35. Thermal Stress Displacement and Stress Fringe Plots