Customer Training Material
or s op Table of Contents
Heat Transfer
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WS-TOC-1
Release 13.0 November 2010
ANSYS Mechanical Heat Transfer
Workshop Table of Contents
Customer Training Material
1.
ThermaBlar
WS1-1
2
HeatinC goil
WS2-1
3
ThermaC l ontact
WS3-1
4
RadiatingSystem
W S 4- 1 -
6
FinTubeheatExchanger
7
Soldering Iron
WS7-1
A
PhaseChange(Appendix)
WSA-1
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WS6-1
WS-TOC-2
Release 13.0 November 2010
Customer Training Material
or s op Thermal Bar
Heat Transfer
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WS1-1
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Problem Description
Customer Training Material
• Consider a bar with a cross section of 0.5m by 1.0m which is 10 meters long • We will put a heat flux on one end and specify a temperature on the other end – The bar is made of steel (K = 60.5 W/m2) – Heat flux is 100 W/m2 – Temperature at the end of the bar is 100º C
1.0 m
10 m
.5 m ANSYS, Inc. Proprietary © 2010 ANSYS, Inc. All rights reserved.
WS1-2
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Units Setup
Customer Training Material
• Open Workbench and specify the unit system: Metric (kg, m, s, ºC, A, N, V) • Choose to “Display Values in Project Units”
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WS1-3
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Model Setup
Customer Training Material
1. Open the Workbench Project Schematic and choose a “Steady State Thermal” analysis system from the toolbox
2. Highlight the Geometry branch, RMB and Browse . . . , to file “Bar_WS1.x_t”
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WS1-4
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Model Setup
Customer Training Material
3. Double click the “Model” branch to open the geometry in Mechanical
4. Highlight the “Steady State Thermal” 5. Scope a heat flux load to one end of the bar (100 W/m2) .
cope a empera ure oa o e opposite end of the bar (100º C)
7. Solve
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WS1-5
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Model Postprocessing
Customer Training Material
8. When the solution completes highlight the Solution branch, RMB and “Insert > Thermal > Temperature” 9. Drag and drop the “Temperature” load branch onto the Solution branch –
•
This is a shortcut to requesting reactions at a constraint
RMB and “Evaluate All Results”
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WS1-6
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Model Postprocessing
Customer Training Material
11. As a model check, review the reaction probe result for the temperature load –
Recall the area where the temperature is applied is 0.5 m2 (0.5x1.0)
–
Since applied heat flux was 100 W/m2, we should find a reaction of 50 W
12. Check the temperature distribution by highlighting the temperature result
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WS1-7
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Model Verification
Customer Training Material
13. In this simple case we are able to figure out the temperature at the hottest end by hand –
The basic heat flow equation:
= −k
A
dz
qΔz
–
The thermal gradient is constant so:
–
The solution for T matches the value for the hot
+ T1 = T2
temperature shown earlieron the Simulation temperature plot
50(10)
.
0.5(60.5) ANSYS, Inc. Proprietary © 2010 ANSYS, Inc. All rights reserved.
WS1-8
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Alternate Solution •
Customer Training Material
It follows that we could replace the heat flux load of 100 Watts/m2 with a heat flow of 50 watts and get the same result
14. Remove Heat flux (delete or suppress): –
Highlight the Heat Flux load, right click and choose delete/suppress
15. Add Heat flow (highlight S-S Thermal branch): •
Highlight the end of the bar
•
RMB > Insert > Heat Flow
•
Specify 50 W for magnitude
. –
Verify that the answer has not changed
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WS1-9
Release 13.0 December 2010
Customer Training Material
or s op H e a t in C o il
Heat Transfer
ANSYS, Inc. Proprietary © 2010 ANSYS, Inc. All rights reserved.
WS2-1
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Problem Description
Customer Training Material
• This model consists of a tungsten coil that is generating heat due to electrical resistance. The load is simulated using internal heat generation. We further assume the coil operates in a vacuum so the only heat transfer mechanism is radiation.
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WS2-2
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Units Setup
Customer Training Material
• Open Workbench and specify the unit system, Metric (kg, mm, s, ºC, mA, N, mV). • Choose to “Display Values in Project Units”.
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WS2-3
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Model Setup
Customer Training Material
1. From the Workbench project page toolbox, select a Steady State Thermal analysis system.
2. Double click the Engineering Data cell. 3. In the “Engineering Data” field labeled “Click here to add a ”, •
Tungsten
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WS2-4
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Model Setup
Customer Training Material
4. From the Engineering Data toolbox drag and drop “Isotropic Thermal Conductivity” onto the “Tungsten” cell. .
n er . mm n e so ropc Thermal Conductivity field.
6. Return to Project 7. Ri ht c lick the G eometr cell and import geometry “Heating_Coil_WS2.stp”.
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WS2-5
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Model Setup
Customer Training Material
8. Double click the Model cell to open the Mechanical application.
9. Expand the Geometry branch and “ ” part.
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WS2-6
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Preprocessing
Customer Training Material
10. Change the selection filter to “body” selection. 11. In the graphics window, “RMB > Select All”. 12. RMB > Insert > Internal Heat Generation. – Enter a magnitude = 0.02 W/mm3
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WS2-7
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Preprocessing
Customer Training Material
13. Change the selection filter to “surface” selection. 14. Select one exterior surface (not one of the ends of the coil). 15. Choose to “Extend to Limits”. – The status bar should indicate 3 faces selected.
16. RMB > Insert > Radiation 17. In the radiation details enter: – Emissivity = 0.25 – = º 18. Solve
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WS2-8
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Solution
Customer Training Material
19. While the solution proceeds (or after it’s complete) review the solution information. Change the solution output to “Heat Convergence”. – Note although this was a steady state solution, the radiation boundary condition makes it nonlinear as the convergence behavior shows. We will discuss nonlinear solution options in the next chapter.
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WS2-9
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Postprocessing •
Customer Training Material
Checking for a steady state condition we note: – Volume = 15978 mm3 – Heat generation = 0.02 W/mm3 – Total heat generation = 319.6 W
20. Drag and drop the “Radiation” boundary . – This creates a reaction probe. 21. Evaluate results. , . , 2% of the actual heat generation above. – Again, the next chapter details conditions and .
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WS2-10
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Postprocessing
Customer Training Material
22. Add thermal results and evaluate. – Scoping to individual surfaces can allow more detailed results to be viewed.
Note: mesh variations may cause differences between your results and those shown here.
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WS2-11
Release 13.0 December 2010
Customer Training Material
or s op Thermal Contact
Heat Transfer
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WS3-1
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Problem Description
Customer Training Material
• A set of electrical contacts is to be modeled in both an open and closed configuration. – We’ll assume both parts are structural steel. • While open, the heat load flows only through the “Arm” of the assembly. • When closed the contacts allow heat flow throu h the “Arm” and “Base”. • The contacts are modeled with a gap, so we will use the contact inball control to simulate a closed contact confi uration. Arm Gap Base
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WS3-2
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Problem Description
Customer Training Material
• Boundary Conditions: – Heat flux on end face of arm = 0.5 W/mm2 – Temperature fixed on 2 bottom surfaces of base = 30 ºC – Convection on 5 faces on arm: h = 2e- 4 W/(mm 2* ºC) • No convection on heat flux surface or circular contact region.
– Convection on 8 faces on base: h = 4e -4 W/(mm2* ºC) • No convection on 2 temperature surfaces or circular contact region.
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WS3-3
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Units Setup
Customer Training Material
• Open Workbench and specify the unit system (Metric, kg, mm, s, ºC, mA, N, mV). • Choose to “Display Values in Project Units”.
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WS3-4
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Model Setup
Customer Training Material
1. From the Workbench project page toolbox, select a Steady State Thermal analysis system.
2. Right click the Geometry cell “Contacts_WS3.stp”. . open the Mechanical application.
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WS3-5
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Model Setup
Customer Training Material
4. When the import is complete you will notice that no contact has been defined. This is because the gap is larger than the default search tolerance. We begin by adding manual contact. 5. Highlight the “Connections” branch RMB > Insert > Manual Contact Region. 6. Scope one circular face to the contact region and the other to the target (note, the order is .
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WS3-6
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Model Setup
Customer Training Material
7. In the Advanced contact details change the “Pinball Region” setting to “Radius”. – Recall from chapter 3 that, with bonded and no separation contact, the pinball controls heat flow.
– surfaces are within the pinball radius, heat transfer can occur.
.
n erapn a ra us = . •
mm.
Note a sample pinball is displayed for visual reference once a radius is .
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WS3-7
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Model Setup
Customer Training Material
9. Highlight the “Steady State Thermal” branch and add boundary conditions as described: 10. Highlight the end face of the arm, RMB > Insert > Heat Flux. – Magnitude = 0.5 W/mm2
11. Highlight the 2 bottom surfaces of , Temperature. – Magnitude = 30 ºC
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WS3-8
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Model Setup
Customer Training Material
12. Select 5 faces on the arm (top, bottom, both sides and the opposite end from where the heat flux was applied). 13. RMB > Insert > Convection 2 – Film coefficient = 2e -4 W/(mm * ºC) – Ambient Temperature = 30 ºC
14. Select the 8 faces on the rectangular section of the base not the 2 ends where the temperature load is applied). 15. RMB > Insert > Convection – Film coefficient = 4e -4 W/ mm2 * ºC – Ambient Temperature = 30 ºC
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WS3-9
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Solution
Customer Training Material
•
Note, a default mesh is used of this example. In actual practice, always check the mesh quality and add mesh controls as needed.
•
Since we assume a steady state linear analysis, .
. o ve
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WS3-10
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Postprocessing
Customer Training Material
17. When the solution completes, drag and drop the temperature and both convection loads onto the Solution branch to setup reaction probes. 18. Evaluate All Results. •
Note the reactions from both boundary conditions on the base are essentially zero.
•
Note that the applied heat flux is 0.5 W/mm and the area of the face is 40 mm , which yields a total heat load of 20 W.
•
Reaction on the arm convection = -20 W (steady state verification).
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WS3-11
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Postprocessing
Customer Training Material
19. Add a temperature result and evaluate the result. – Note the temperature distribution within the assembly.
– As expected, no heat is flowing from the
arm to the base since the contact pinball is .
•
Next we will model a condition where the . modify the geometry to close the gap, instead we will increase the pinball size to the next page.
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WS3-12
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Postprocessing
Customer Training Material
20. Return to the schematic and highlight the top cell in the system, RMB > Rename.
.
“
”.
22. Again highlight the top cell in the system, RMB > Duplicate.
23. Repeat steps above to rename the new system the “Contacts Closed”.
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WS3-13
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Model 2 Setup
Customer Training Material
24. Double click the Model cell in the “Contact Closed” system to open the new analysis.
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WS3-14
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Model 2 Setup •
Customer Training Material
Since the model is a duplicate of our srcinal, only the contact needs to be changed.
25. Highlight the contact region and change the pinball radius to 1mm. • The bonded contact type assumes closed contact whenever contact and target faces are within the pinball. we can use this to simulate a closed contact condition here.
26. Solve.
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WS3-15
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Model 2 Postprocessing
Customer Training Material
• Again checking the reactions at the boundary conditions we can verify a steady state heat balance. • RT = 2.3222 W, RC1 = 10.62 W, RC2 = 7.0582 W • RT + RC1 + RC2 = 20 W
– Note mesh differences may cause slight variations in results from those shown here. ANSYS, Inc. Proprietary © 2010 ANSYS, Inc. All rights reserved.
WS3-16
Release 13.0 December 2010
Customer Training Material
or s op R a d ia t in S s t e m
Heat Transfer
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WS4-1
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Problem Description
Customer Training Material
• An aluminum section of fin and tube heat exchanger is to be analyzed. Since the model represents an axially symmetric structure, a 90 section will be modeled. • The tube carries a contained hot fluid and the interior wall is assumed to be at 300C. • The exterior surfaces experience a convective condition. • We will add a radiation boundary condition on the same exterior surfaces to evaluate the impact of radiation losses to the system.
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WS4-2
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Units Setup
Customer Training Material
• Open Workbench and specify the unit system (Metric, kg, mm, s, ºC, mA, N, mV). • Choose to “Display Values in Project Units”.
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WS4-3
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Model Setup
Customer Training Material
1. From the Workbench project page toolbox, select a Steady State Thermal analysis system.
2. Right click the Geometry cell “Fin_Tube_WS6. stp”. . Data cell.
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WS4-4
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Model Setup
Customer Training Material
4. Activate the Engineering Data Sources and highlight General Materials.
5. Add “Aluminum Alloy” to the current ro ect. 6. Return to Project.
7. Double click the Model cell to open the Mechanical application.
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WS4-5
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Preprocessing
Customer Training Material
8. Expand the Model branch and highlight the part “FinTube”. 9. In the details change the material assignment to “Aluminum Alloy”.
•
A check in engineering data will confirm the aluminum’s thermal conductivity property is .
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WS4-6
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Preprocessing
Customer Training Material
10. Highlight the mesh branch. 11. Select the 2 s mmetr faces RMB > Insert > Sizing.
12. Set “Element Size” to 2 mm.
.
, Generate Mesh.
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WS4-7
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Preprocessing
Customer Training Material
14. Highlight the “Steady State Thermal” branch. 15. Highlight the interior wall of the tube section, RMB > Insert > Temperature.
16. In the details for the temperature load enter 300 in the Ma nitude field.
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WS4-8
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Preprocessing •
Customer Training Material
Make sure surface select mode is active.
17. In the graphics window, RMB > Select All. 18. Use the control ke and unselect the interior ends and symmetry faces of the fin tube model (5 faces in all). – When finished ou should have 33 faces selected.
19. RMB > Insert > Convection.
•
Continued . . .
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WS4-9
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Preprocessing
Customer Training Material
20. Enter a Film Coefficient = 5e-4 W/(mm^2-C) . 21. Enter Ambient Temperature = 30 ºC.
22. Repeat steps a and b (select 33 faces). 23. RMB > Insert > Radiation. • •
Enter Ambient Temperature = 30C. Leave Emissivity = 1
•
Leave Correlation = To Ambient
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WS4-10
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Solution
Customer Training Material
24. Solve: 25. Highlight the Temperature, Convection and Radiation loads and drag and drop them into the Solution branch: – This is a shortcut to setting up reaction probes for boundary conditions.
26. RMB > Evaluate All Results. 27. Analysis shows we have an energy balance.
Rt – Rc – Rr = Rtot
4750.9 – 4624.6 –126.27 = 0.03
Reactions show that radiation accounts for roughly 2.5% of heat losses from the system. ANSYS, Inc. Proprietary © 2010 ANSYS, Inc. All rights reserved.
WS4-11
Release 13.0 December 2010
Customer Training Material
or s op Solenoid
Heat Transfer
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WS5-1
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Problem Description
Customer Training Material
• This model represents an electrical solenoid composed of several different materials. • An iron core is surrounded by copper, separated by a plastic insulator. The coil is su orted on a steel bracket. • The iron core is generating heat at a rate of 0.001 W/mm2, while the surface of the copper experiences natural convection. One face of the bracket is constrained to a fixed temperature.
• Goal: determine the temperature distribution in the solenoid assuming the evc e asr eac e as ea ys a e. ANSYS, Inc. Proprietary © 2010 ANSYS, Inc. All rights reserved.
WS5-2
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Units Setup
Customer Training Material
• Open Workbench and specify the unit system (Metric, kg, mm, s, ºC, mA, N, mV). • Choose to “Display Values in Project Units”.
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WS5-3
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Model Setup
Customer Training Material
1. From the Workbench project page toolbox, select a Steady State Thermal analysis system.
. Data 3. From the “General Materials •
Copper Alloy
•
Gray Cast Iron
•
oy e
ye ne
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WS5-4
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Model Setup
Customer Training Material
4. Right click the Geometry cell and import geometry “Solenoid_WS5.stp”.
. Mechanical application. . materials for each part as shown earlier .
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WS5-5
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Preprocessing
Customer Training Material
7. Highlight the Mesh branch and expand the “Sizing” section in the details. 8. Change the “Relevance Center” to “Medium”. 9. Highlight the mesh branch, RMB > Generate.
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WS5-6
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Preprocessing
Customer Training Material
12. Highlight the “Steady State Thermal” branch and select the “core” part. 13. RMB > Insert > Internal Heat Generation.
14. In the details for the heat generation input a magnitude of 0.001 W/mm3.
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WS5-7
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Preprocessing
Customer Training Material
15. Activate face selection and select the 8 exterior and 3 top surfaces of the solenoid (11 total).
16. RMB > Insert > Convection.
17. In the details enter the convection properties: – Film Coefficient = 5e -5 W/(mm2 x ºC) – Ambient Tem erature = 25 ºC
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WS5-8
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Preprocessing
Customer Training Material
18. Select one side face on the bracket part. 19. RMB > Insert > Temperature. 20. Enter a magnitude of 25 ºC.
•
Since we’ve assumed a linear steady state condition all analysis settings will remain in their default .
21. Solve
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WS5-9
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Postprocessing
Customer Training Material
•
Before reviewing results let’s first verify that we have a steady state condition as expected.
•
The applied heat generation was 0.001 W/mm3 to the core.
•
By inspecting the properties of the core we can see the volume of the core is 44,698 mm3. – The resulting heat dissipated through the temperature boundary and the convection should be: 0.001 W/mm3 x 44698 mm3 = 44.698 W.
22. Using the control key, highlight both the convection and temperature boundary conditions. 23. Drag and drop the loads onto the Solution branch. – The result is 2 reaction probes are automatically nser e .
24. RMB > Evaluate All Results ANSYS, Inc. Proprietary © 2010 ANSYS, Inc. All rights reserved.
WS5-10
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Postprocessing
Customer Training Material
• The details for each of the reaction probes show we have an energy balance: – Convection reaction = -9.8475 W – Temperature reaction = -34.85 W – RT + RC = - 44.6975 W – Recall heat input from previous page.
–
Note: may variations. vary slightly from those shownyour due results to meshing
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WS5-11
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Postprocessing
Customer Training Material
25. Insert a Temperature result to the Solution branch. 26. Evaluate All Results – Due to the extremes in the model, little variation in temperature can be seen in this plot.
27. Activate body selection and select only the insulator part, then repeat the above steps.
Full Model ANSYS, Inc. Proprietary © 2010 ANSYS, Inc. All rights reserved.
Scoped Model WS5-12
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Postprocessing
Customer Training Material
28. Highlight the solution branch and insert Total Heat Flux. – Although contours for heat flux can be displayed, often a vector plot is instructive for directional quantities.
29. Activate the vector plot mode. 30. Use the vector controls to adjust the display (e.g. vector length, density, etc.).
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WS5-13
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Postprocessing
Customer Training Material
•
Next we would like to see how the temperature varies along a path within the solenoid.
•
Begin by adding 2 local coordinate systems.
31. Change “Define by” to “Global Coordinates”. 32. Use the following srcin locations for each: – , , =, , – CS 2: X, Y, Z = 23, 50, 38
Example
. “Construction Geometry”.
34. From the construction geometry branch RMB > Insert > Path”.
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WS5-14
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Postprocessing
Customer Training Material
35. In the details for the Path, switch the starting and ending locations to the local coordinate systems just created. – Note, in the example shown the coordinate systems were renamed to “start” and “end”.
36. Insert a new temperature result in the Solution. 37. Switch to “Path” as the Scoping Method. . ANSYS, Inc. Proprietary © 2010 ANSYS, Inc. All rights reserved.
.
WS5-15
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Postprocessing
Customer Training Material
• Evaluate All Results.
Graph shows temperature variation along path
Contour displayed along path
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WS5-16
Release 13.0 December 2010
Customer Training Material
or s op Fin Tube Heat Exchanger
Heat Transfer
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WS6-1
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Problem Description
Customer Training Material
• An aluminum section of fin and tube heat exchanger is to be analyzed. Since the model represents an axially symmetric structure, a 90 section will be modeled. • The tube carries a contained hot fluid while the exterior surfaces experience a convective condition. • It has been determined that the fluid causes a wall temperature of 200 C at the entrance and 150 C wall temperature at the exit. We will use a function load to apply this temperature
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WS6-2
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Units Setup
Customer Training Material
• Open Workbench and specify the unit system (Metric, kg, mm, s, ºC, mA, N, mV). • Choose to “Display Values in Project Units”.
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WS6-3
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Model Setup
Customer Training Material
1. From the Workbench project page toolbox, select a Steady State Thermal analysis system.
2. Right click the Geometry cell “Fin_Tube_WS6. stp”. . Data cell.
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WS6-4
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Model Setup
Customer Training Material
4. Activate the Engineering Data Sources and highlight General Materials.
5. Add “Aluminum Alloy” to the current ro ect. 6. Return to Project.
7. Double click the Model cell to open the Mechanical application.
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WS6-5
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Preprocessing
Customer Training Material
8. Expand the Model branch and highlight the part “FinTube”. 9. In the details change the material assignment to “Aluminum Alloy”.
•
A check in engineering data will confirm the aluminum’s thermal conductivity property is .
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WS6-6
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Preprocessing
Customer Training Material
10. Highlight the mesh branch. 11. Select the 2 s mmetr faces RMB > Insert > Sizing.
12. Set “Element Size” to 2 mm.
.
, Generate Mesh.
ANSYS, Inc. Proprietary © 2010 ANSYS, Inc. All rights reserved.
WS6-7
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Preprocessing
Customer Training Material
• When complete, inspect the resulting mesh. – Note, if desired you may mesh without the size control for comparison. The default mesh is quite coarse for this model.
Default Mesh
Size Controlled Mesh
ANSYS, Inc. Proprietary © 2010 ANSYS, Inc. All rights reserved.
WS6-8
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Preprocessing
Customer Training Material
14. Highlight the “Steady State Thermal” branch. 15. Highlight the interior wall of the tube section, RMB > Insert > Temperature.
16. In the details for the temperature load chan e the ma nitude field from “Constant” to “Function. . field: 1. 200 – 0.25*y
. ANSYS, Inc. Proprietary © 2010 ANSYS, Inc. All rights reserved.
WS6-9
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Preprocessing
Customer Training Material
• By highlighting the Temperature branch in the tree, the load variation is displayed as a contour.
ANSYS, Inc. Proprietary © 2010 ANSYS, Inc. All rights reserved.
WS6-10
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Preprocessing •
Customer Training Material
Make sure surface select mode is active.
19. In the graphics window, RMB > Select All. 20. Use the control ke and unselect the interior ends and symmetry faces of the fin tube model (5 faces in all). – When finished ou should have 33 faces selected.
21. RMB > Insert > Convection.
•
Continued . . .
ANSYS, Inc. Proprietary © 2010 ANSYS, Inc. All rights reserved.
WS6-11
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Preprocessing
Customer Training Material
22. Change the Film Coefficient field to “Tabular (Temperature)”. 23. Enter Ambient Temperature = 30 ºC 24. Enter the coefficient values shown in the convection table.
Temperature ºC
H (W/mm 2*ºC)
0
0.004
10
0.0054
20
0.006
40
0.0066
60
0.007
100
0.0077
Convection Coefficient h(T)
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WS6-12
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Solution
Customer Training Material
25. Solve: – Although there are temperature dependent materials and boundary conditions, the output shows that the solution converges quickly (2 era ons .
26. Highlight the Temperature and Convection loads and drag and drop them into the Solution branch: – This is a shortcut to setting up reaction probes for boundary conditions. 27. Evaluate All Results. •
agreement between input and output heat.
ANSYS, Inc. Proprietary © 2010 ANSYS, Inc. All rights reserved.
WS6-13
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Postprocessing
Customer Training Material
28. Insert a temperature result and evaluate. Note the temperature variation along the Y direction.
ANSYS, Inc. Proprietary © 2010 ANSYS, Inc. All rights reserved.
WS6-14
Release 13.0 December 2010
Customer Training Material
or s op S o ld e r in Ir o n
Heat Transfer
ANSYS, Inc. Proprietary © 2010 ANSYS, Inc. All rights reserved.
WS7-1
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Problem Description
Customer Training Material
• An electric soldering iron is to be powered by an oscillating current. We will apply an oscillating heat generation to the tip of the model to simulate this power cycle. • Our goal is to estimate when steady state is reached and examine the temperature distribution.
Analysis Model
Soldering Iron ANSYS, Inc. Proprietary © 2010 ANSYS, Inc. All rights reserved.
WS7-2
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Problem Description
Customer Training Material
• Boundary Conditions: – The initial temperature is 30 ºC. – The 2 attachment points are assumed to be fixed at a constant 40 ºC. – The exterior experiences convection at h = 5e-4 W/(mm2*ºC), TA = 30 ºC. – The tip section is generating heat defined by 1+cos(180*time) W/mm3 • This function provides an alternating 2 W/mm3 heat generation at a 2 second period.
ANSYS, Inc. Proprietary © 2010 ANSYS, Inc. All rights reserved.
WS7-3
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Units Setup
Customer Training Material
• Open Workbench and specify the unit system, Metric (kg, mm, s, ºC, mA, N, mV). • Choose to “Display Values in Project Units”.
ANSYS, Inc. Proprietary © 2010 ANSYS, Inc. All rights reserved.
WS7-4
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Model Setup
Customer Training Material
1. From the Workbench project page toolbox, select a Transient Thermal analysis system.
2. Right click the Geometry cell “Soldering_Iron_WS7.stp”. . Data cell.
ANSYS, Inc. Proprietary © 2010 ANSYS, Inc. All rights reserved.
WS7-5
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Model Setup
Customer Training Material
4. Activate the Engineering Data Sources, then highlight General Materials. 5. Add “Copper Alloy” to the current project. 6. Return to Project.
7. Double click the Model cell to open the Mechanical application.
ANSYS, Inc. Proprietary © 2010 ANSYS, Inc. All rights reserved.
WS7-6
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Preprocessing
Customer Training Material
8. Expand the Geometry branch and highlight the 3 parts (use Shift key). 9. In the details change the material assignment to “Copper Alloy”.
10. Highlight the Mesh branch and, under sizing, set the element size to 1mm. – could be added here to afford hex meshing, more refined shapes and sizes, etc..
11. RMB > Generate Mesh
ANSYS, Inc. Proprietary © 2010 ANSYS, Inc. All rights reserved.
WS7-7
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Preprocessing
Customer Training Material
12. Highlight “Initial Temperature” and set to 30 ºC.
.
“
”
•
Step End Time = 20s
•
Auto Time Stepping = ON .
•
Note, the default maximum time step was 2 s. The sizes however we have fewer solutions points to postprocess. We have reduced the max time step to 0.25 s to provide more solution points.
ANSYS, Inc. Proprietary © 2010 ANSYS, Inc. All rights reserved.
WS7-8
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Preprocessing
Customer Training Material
14. Highlight the “Transient Thermal” branch. 15. Select the 2 end surfaces of the model. 16. RMB > Insert > Temperature. •
Enter a ma nitude = 40 ºC.
17. Select the exterior surfaces of the model excludin the 2 end surfaces above (40 faces). 18. RMB > Insert > Convection: •
Film Coefficient = 5e-4 W/ mm2*ºC
•
Ambient Temp = 30 ºC
ANSYS, Inc. Proprietary © 2010 ANSYS, Inc. All rights reserved.
WS7-9
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Preprocessing
Customer Training Material
19. Activate the body selection filter and select the body “Tip”. 20. RMB > Insert > Internal Heat Generation. 21. Click in the “Magnitude” field and choose “Function” from the fly out menu. 22. In the “Ma nitude” field enter the function: 1 + cos(100*time). •
The result is a sinusoidal heat generation as is shown here:
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WS7-10
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Solution
Customer Training Material
23. Solve. •
Note, during a transient thermal solution the Solution Information can be tracked (as with other analyses). In addition the global maximum and minimum temperatures can be followed graphically in real time.
ANSYS, Inc. Proprietary © 2010 ANSYS, Inc. All rights reserved.
WS7-11
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Postprocessing
Customer Training Material
24. When the solution is complete, insert three Temperature results for: – Scoped to all bodies. – Scoped to only the Tip. – Scoped to the front surface of the Tip. 25. Evaluate All Results.
ANSYS, Inc. Proprietary © 2010 ANSYS, Inc. All rights reserved.
WS7-12
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Postprocessing
Customer Training Material
26. Highlight the result branch for all bodies. 27. In the details change from “Temperature By Time” to “By Maximum Over Time”. 28. Evaluate All Results. – Note the maximum temperature in the model over the course of the solution is approximately 600 ºC and occurs on the Tip.
ANSYS, Inc. Proprietary © 2010 ANSYS, Inc. All rights reserved.
WS7-13
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Postprocessing
Customer Training Material
• A plot of the global maximum temperature indicates that the maximum temperatures appear to be reaching a steady state at approximately 15 seconds.
ANSYS, Inc. Proprietary © 2010 ANSYS, Inc. All rights reserved.
WS7-14
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Postprocessing •
Customer Training Material
Obtain reaction solutions from the temperature and convection boundary conditions:
29. Highlight Temperature and Convection and drag and drop onto the Solution branch. •
Plot the time varying heat generation load along with the reactions.
30. Highlight “Internal Heat Generation”, “Reaction Probe” and “Reaction Probe 2”. 31. Click the “New Chart and Table” icon.
ANSYS, Inc. Proprietary © 2010 ANSYS, Inc. All rights reserved.
WS7-15
Release 13.0 December 2010
Customer Training Material
or s op
p p en x
P h ase C h an e
Heat Transfer
ANSYS, Inc. Proprietary © 2010 ANSYS, Inc. All rights reserved.
WSA-1
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Problem Description
Customer Training Material
• The model represents cooling of molten aluminum contained in a sand cast for a wheel. – The aluminum has a melting point of 696 ºC. • To economize the analysis will be conducted using a 2D axisymmetry model of the wheel and mold.
ANSYS, Inc. Proprietary © 2010 ANSYS, Inc. All rights reserved.
WSA-2
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Problem Description
Customer Training Material
• Since this is a phase change problem we’ll need to include enthalpy as a material property. To do this we need to use a command object. The basic properties are shown below. Later in the workshop we will use this data to construct a table representing enthalpy versus temperature. • Aluminum Alloy: – Density = 2770 kg/m3 – Specific Heat (solid) = 876 J/(kg* ºC) – Specific Heat (liquid) = 1050 J/(kg* ºC) – Melting Temperature = 696 ºC – Transition Temperature = 695 ºC – Liquid Temperature = 697 ºC – Latent Heat = 395440 J/kg
ANSYS, Inc. Proprietary © 2010 ANSYS, Inc. All rights reserved.
WSA-3
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Units Setup
Customer Training Material
• Open Workbench and specify the unit system Metric (kg, m, s, ºC, A, N, V). • Choose to “Display Values in Project Units”.
ANSYS, Inc. Proprietary © 2010 ANSYS, Inc. All rights reserved.
WSA-4
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Open Project
Customer Training Material
• From Workbench choose, “File > Restore Archive . . . “.
• Browse to and open the Workbench archive “WheelMold.wbpz”.
• When rom ted Save usin the default name “WheelMold”. ANSYS, Inc. Proprietary © 2010 ANSYS, Inc. All rights reserved.
WSA-5
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Model Setup
Customer Training Material
1. From the Workbench project page toolbox, drag a Transient Thermal analysis system onto the Geometry cell. 2. Double click the Engineering Data.
3. Highlight the Engineering Data cell and enter “Sand” as a new material.
ANSYS, Inc. Proprietary © 2010 ANSYS, Inc. All rights reserved.
WSA-6
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Model Setup
Customer Training Material
4. From the Toolbox drag and drop Density, Isotropic Thermal Conductivity and Specific Heat onto the “Sand” property. 5. Enter the property values: – Density = 1520 kg/m3 – Conductivity = 0.346 W/(m* ºC) – Specific Heat = 816 J/(kg* ºC)
6. Click the icon to activate the Engineering Data Sources.
ANSYS, Inc. Proprietary © 2010 ANSYS, Inc. All rights reserved.
WSA-7
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Model Setup
Customer Training Material
7. Highlight “General Materials”.
.
.
9. Deactivate the data sources b to
l i n th e
Data Sources icon.
ANSYS, Inc. Proprietary © 2010 ANSYS, Inc. All rights reserved.
WSA-8
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Model Setup
Customer Training Material
10. Highlight “Aluminum Alloy”. 11. Usin the ro erties shown in the table (and below), enter new data for the aluminum alloy thermal conductivity. •
Conductivity table:
•
0
:
206
•
100 :
208
•
200 :
215
•
300 :
228
• •
400 : 530 :
248 268
•
800 :
290
ANSYS, Inc. Proprietary © 2010 ANSYS, Inc. All rights reserved.
WSA-9
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Model Setup
Customer Training Material
12. Return to the project schematic. 13. Hi hli ht the Geometr cell RMB > Properties.
14. In the Advanced Geometry Options verify to 2D. that the “Analysis Type” is set
ANSYS, Inc. Proprietary © 2010 ANSYS, Inc. All rights reserved.
WSA-10
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Model Setup
Customer Training Material
15. Double click the Model cell to open the Mechanical application.
16. Highlight the Geometry branch and set the 2D Behavior to “Axisymmetric” .
ANSYS, Inc. Proprietary © 2010 ANSYS, Inc. All rights reserved.
WSA-11
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Model Setup
Customer Training Material
17. Highlight the part, “Mold” and assign the material “Sand”.
18. Highlight the part, “Wheel” and assign the material “Aluminum Allo ”. •
Note, for phase change problems, the property enthalpy is used which is defined in terms of density and specific heat. Since enthalpy is not supported in the engineering data application we need to add a command object to define it. The enthalpy property specific heat in engineering data.
ANSYS, Inc. Proprietary © 2010 ANSYS, Inc. All rights reserved.
WSA-12
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Model Setup
Customer Training Material
19. Highlight the “Wheel” part, RMB > Insert Commands.
20. Using the aluminum properties earlier and the equations 7-19 we calculate enthalpy as a shown function of temperature E(T) as: on – = – E(695) = 1.6857e9 – E(697) = 2.7614e9 – = .
21. Enter the “mptemp” and “mpdata” commands as shown in the
ANSYS, Inc. Proprietary © 2010 ANSYS, Inc. All rights reserved.
WSA-13
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Model Setup
Customer Training Material
22. Activate the body selection filter and, in the graphics window, “RMB > Select All”.
.
.
24. In the Body Sizing details set “Element Size” = 0.01 m.
25. Hi hli ht the Mesh branch RMB > Generate Mesh. ANSYS, Inc. Proprietary © 2010 ANSYS, Inc. All rights reserved.
WSA-14
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Solution Setup
Customer Training Material
26. Highlight “Initial Temperature” and set to 30 ºC.
27. Highlight “Analysis Settings” and set auto time ste in as shown below. – This will be a 2 step solution. • The first step has a duration of 0.1s where the initial temperature load for the aluminum will be applied. • In the second step (25 minutes or 1500 seconds) the temperature willto be removed and the aluminum allowedload to cool solidification. • See details on next slide. ANSYS, Inc. Proprietary © 2010 ANSYS, Inc. All rights reserved.
WSA-15
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Solution Setup
Customer Training Material
• Step 1: – Auto Time Stepping = On – End time = 0.1 s – Initial time step = 1e-3 s – Minimum time step = 1e-3 s – Maximum time step = 0.1 s
• Step 2: – Auto Time Ste in = On – End time = 1500 s – Initial time step = 1e-3 s – Minimum time ste = 1e-4 s – Maximum time step = 5 s
ANSYS, Inc. Proprietary © 2010 ANSYS, Inc. All rights reserved.
WSA-16
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Boundary Conditions
Customer Training Material
28. Highlight the “Transient Thermal” branch. 29. Select the to line on the mold and RMB > Insert > Convection. Details: – Film Coefficient = 5.75 W/(m2* ºC) – Ambient Tem erature = 30 ºC
. Insert > Convection. Details: – Film Coefficient = 7.5 W/(m2* ºC) – = º
ANSYS, Inc. Proprietary © 2010 ANSYS, Inc. All rights reserved.
WSA-17
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Boundary Conditions
Customer Training Material
31. Change the selection filter to body select and select the Wheel part. 32. RMB > Insert > Temperature.
33. Enter a Magnitude = 800 C. 34. RMB step 2 (t = 1500s) and “Activate/Deactivate at this step!” – o e, eac va ng e empera ure a
s point removes the temperature load during the second step. This is NOT the same as setting the temperature to zero.
ANSYS, Inc. Proprietary © 2010 ANSYS, Inc. All rights reserved.
WSA-18
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Solution and Results
Customer Training Material
35. Solve the model. – Note, solution times will vary depending on hardware. •
When the solution is complete insert temperature results for the entire model to review.
Recall from the model setup that the melting temperature of the aluminum is 696 C. A 3 color legend can be setup to show solidification over time
ANSYS, Inc. Proprietary © 2010 ANSYS, Inc. All rights reserved.
WSA-19
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Solution and Results
Customer Training Material
• A plot of the global maximum temperature shows a relatively flat cooling profile in the alum inum’s transition region (695 – 697 ºC). • Once solidification is complete the cooling proceeds at an increased rate. Transition Region
≈
696 ºC
ANSYS, Inc. Proprietary © 2010 ANSYS, Inc. All rights reserved.
WSA-20
Release 13.0 December 2010
ANSYS Mechanical Heat Transfer
Solution and Results
Customer Training Material
• By locating coordinate systems at desired locations and attaching temperature probes to the wheel, a chart can be constructed showing temperature over time at each location.
ANSYS, Inc. Proprietary © 2010 ANSYS, Inc. All rights reserved.
WSA-21
Release 13.0 December 2010