Project Report AnSys Workbench - Nithin L Devasia

Project Report on Ansys FLUENT AND STRUCTURAL ANALYSIS OF NACA 4515 AEROFOIL

Subm Su bmiitt tteed B :

NITHIN L DEVASIA

VANROSS Jn. THIRUVANANTHAPURAM

Certificate This is to certify that this project report entitled “FLUENT AND STRUCTURAL ANALYSIS OF N ACA

4515

AEROFOIL” is a complete record of the work done by NITHIN L DEVASIA for the requirement of the award of

course on MASTER DIPLOMA IN PRODUCT DESIGN AND ANALYSIS during the year 2014 from CADD CENTRE, VANROSS Jn. THIRUVANANTHAPURAM THIRUVANANTHAPURAM..

Guided by:

Verified by:

Mr. RAHUL KRISHNAN Senior CADD Engineer CADD CENTRE Vanross Jn.

Mr. TINU V G Technical Leader CADD CENTRE Vanross Jn.

CADD Centre Thiruvananthapuram | Ansys Workbench | 1

ACKNOWLEDGEMENT

I also want to thank the CADD Centre Thiruvananthapuram, for giving me quality training in Ansys Workbench and providing me the opportunity and facilities to pursue this project and present the report.

I take this opportunity to express my deep sense of gratitude to my concerned faculty, Mr. Rahul Krishnan – Senior CADD Engineer of CADD Centre, Vanross Junction, Thiruvananthapuram for his valuable suggestions and guidance, especially for the technical information imparted by him in both theory and practical session.

I

also

use

this

opportunity

to

express

my

heartfelt

thanks

to

Mr. TINU V G, Technical Leader of CADD Centre, for the encouragement

provided by him throughout my course.

I appreciate the team who made the efforts to create the CADD Centre course material in such a simple and effective manner. It really motivated me to explore more on the software further.

Last but not the least, I accord myself the privilege of thanking all other members of CADD Centre who were directly and indirectly connected to this project.

Nithin L Devasia


Table of Contents

PREFACE ............................................................................................................................................. 4 ABOUT CAE ................................................ .................................................................................... 5 ANSYS and its CAPABILITIES ...................................................................................................... 8 ABOUT THE PROJECT .................................................................................................................... 14 SCOPE OF THE PROJECT and PROBLEM DEFININTION ............................................. ........... 20 APPROACH AND PROCEDURE .............................................. ....................................................... 21 INFERENCE....................................................................................................................................... 60 SUGGESTIONS AND CONCLUSIONS........................................................................................... 61 REFERENCE ...................................................................................................................................... 62


PREFACE

Nowadays we are depending more on computers due to their speed in data processing, visualization capabilities, data storing in documentation as well as numerical calculations etc. They have become an integral part of everyone’s daily life. They find applications in communication, entertainment, accounting, and scientific research and in production industries.

In production industries, computers are used from designing, controlling manufacturing operations, etc., increasing efficiency and productivity. This particular field of application being called Precise Engineering Cycle is further classified into Computer Aided Designing (CAD), Computer Aided Engineering (CAE) and Computer Aided Manufacturing (CAM).

The product designers are posted with challenge to bring out products that could exceed the expectations of the consumer consistently in product quality, price and performance. Design engineers are constantly working on these challenges in order to enhance the product quality and performance while reducing cost. Computer Aided Engineering (CAE) tools assists design engineers in achieving the challenges posted to them time to time. There are of many application packages which all particularly strong in specific areas of CAE. But there are also ones that have good all-round capabilities like ANSYS, Altair HyperWorks, Abaqus, ADINA etc.


ABOUT CAE

Computer aided engineering (CAE) refers to a collection of software and hardware tools integrated into a system (computer) that is providing the circuit designer and circuit troubleshooter with step-by-step assistance during each phase of the design and analysis cycle, as well as during development, documentation, and maintenance. Under the CAE umbrella a number of commonly called "automated design tools," which are the software components of CAE, are revolutionizing and transforming engineering environments from the "hands-on' way of conducting business into a virtual or simulated "hands-on" mode of operating; and are having a tremendous impact throughout all engineering disciplines. They have not yet displaced bread boarding and other methods of developing circuit boards yet but are making their presence known to the point of being totally necessary in the design of certain devices. It is the intention of this report to promote the use of these tools in the government by providing engineering management with an overview of the hardware and software products available for electronic simulation, while covering trends, new technologies, and costs.

CAE is also defined very broadly as ―The computer tools used to assist in engineering design, development and optimization tasks. ―Models of systems may be separated into static or dynamic systems, each having a particular purpose. Static models are independent of time. Dynamic models are time varying.

Software tools that have been developed to support these activities are considered CAE tools. CAE tools are being used, for example, to analyze the robustness and performance of components and assemblies. The term encompasses simulation, validation, and optimization of products and manufacturing tools. In the future, CADD Centre Thiruvananthapuram | Ansys Workbench | 5

CAE systems will be major providers of information to help support design teams in decision making. In regard to information networks, CAE systems are individually considered a single node on a total information network and each node may interact with other nodes on the network. CAE systems can provide support to businesses. This is achieved by the use of reference architectures and their ability to place information views on the business process. Reference architecture is the basis from which information model, especially product and manufacturing models. The term CAE has also been used by some in the past to describe the use of computer technology within engineering in a broader sense than just engineering analysis. It was in this context that the term was coined by Jason Lemon, founder of SDRC in the late 1970s. This definition is however better known today by the terms CAx and PLM. CAE areas covered include: 

Stress analysis on components and assemblies using FEA (Finite Element Analysis).



Thermal and fluid flow analysis Computational fluid dynamics (CFD).



Multibody dynamics (MBD) & Kinematics.



Analysis tools for process simulation for operations such as casting, molding, and die press forming.



Optimization of the product or process.



Safety analysis of postulate loss-of-coolant accident in nuclear reactor using realistic thermal-hydraulics code.


In general, there are three phases in any computer-aided engineering task: 

Pre-processing – defining the model and environmental factors to be applied to it. (typically a finite element model, but facet, voxel and thin sheet methods are also used)





Analysis solver (usually performed on high powered computers) Post-processing of results (using visualization tools)

This cycle is iterated, often many times, either manually or with the use of commercial optimization software. CAE tools are very widely used in the automotive industry. In fact, their use has enabled the automakers to reduce product development cost and time while improving the safety, comfort, and durability of the vehicles they produce. The predictive capability of CAE tools has progressed to the point where much of the design verification is now done using computer simulations rather than physical prototype testing.

CAE dependability is based upon all proper assumptions as inputs and must identify critical inputs. Even though there have been many advances in CAE, and it is widely used in the engineering field, physical testing is still used as a final confirmation for subsystems due to the fact that CAE cannot predict all variables in complex assemblies (i.e. metal stretch, thinning).


Modeling & Analysis

Drafting & Design

 Dynamic

NSYS and its CAPABILITIES

 Design .



for assembly

Computer aided manufacture

analysis  Rapid control prototyping  Finite element analysis  Mechanism design  Discrete event simulation

Computer Aided Engineering

Manufacture  Computer

aided part programming (CNC)  Distributed numerical control  Coordinate measuring  Flexible assembly/manufacturin g systems

Production Planning & Control  Scheduling

Quality control  Materials requirements planning  Just-in-time manufacturing


ANSYS and its CAPABILITIES

ANSYS Workbench is the framework upon which the industry’s broadest suite of advanced engineering simulation technology is built. An innovative project schematic view ties together the entire simulation process, guiding the user every step of the way. Even complex multiphysics analyses can be performed with dragand-drop simplicity. With bi-directional CAD connectivity, an automated project update mechanism, pervasive parameter management and integrated optimization tools, the ANSYS Workbench platform delivers unprecedented productivity that truly enables Simulation Driven Product Development. The ANSYS Workbench framework hosts the following software products and components: COMMON TOOLS AND CAPABILITIES • ANSYS CAD connections • ANSYS Design Modeler • ANSYS Meshing • ANSYS DesignXplorer • FE Modeler

FLUID DYNAMICS • ANSYS CFX • ANSYS FLUENT • ANSYS Icepak • ANSYS POLYFLOW ANSYS Multiphysics CADD Centre Thiruvananthapuram | Ansys Workbench | 9

STRUCTURAL MECHANICS • ANSYS Mechanical • ANSYS Structural • ANSYS Professional EXPLICIT DYNAMICS • ANSYS Explicit STR • ANSYS AUTODYN • ANSYS LS-DYNA (setup-only in ANSYS Workbench) ELECTROMAGNETICS • ANSYS Emag TURBO SYSTEM • ANSYS BladeModeler • ANSYS TurboGrid • ANSYS Vista TF OFFSHORE • ANSYS AQWA


ANSYS Workbench Features 

Bidirectional, parametric links with all major CAD systems



Integrated, analysis-focused geometry modeling, repair, and



simplification via ANSYS DesignModeler



Highly-automated, physics-aware meshing



Automatic contact detection



Unequalled depth of capabilities within individual physics disciplines



Unparalleled breadth of simulation technologies



Complete analysis systems that guide the user start-to-finish through an analysis



Comprehensive multiphysics simulation with drag-and-drop ease of use



Flexible components enable tools to be deployed to best suit engineering intent



Innovative project schematic view allows engineering intent, data relationships, and the state of the project to be comprehended at a glance Complex project schematics can be saved for re-use



Pervasive, project-level parameter management across all physics



Automated what-if analyses with integrated design point capability



Adaptive architecture with scripting and journaling capabilities and API’s enabling rapid integration of new and third-party solutions

Drag-and-Drop Multiphysics

The ANSYS Workbench platform has been engineered for scalability. Building complex, coupled analyses involving multiple physics is as easy as dragging in a follow-on analysis system and dropping it onto the source analysis. Required data CADD Centre Thiruvananthapuram | Ansys Workbench | 11

transfer connections are formed automatically. As an example, consider the oneway fluid structure interaction (FSI) simulation shown schematically below.

Drag-and-drop multiphysics: forming a link in the project schematic (at left) achieves data transfer between the different physics, and creates imported loads in the downstream simulation (shown inside the ANSYS Mechanical application at right).

The ANSYS Workbench platform automatically forms a connection to share the geometry for both the fluid and structural analyses, minimizing data storage and making it easy to study the effects of geometry changes on both analyses. In addition, a connection is formed to automatically transfer pressure loads from the fluid analysis to the structural analysis.


Flexible Project Construction

Complete analysis systems are convenient because they contain all of the necessary tasks or components to complete start-to-finish simulations for a wide variety of physics. The project schematic has also been designed to be very flexible. You can connect component systems — task-oriented, ―building block‖ systems— in a wide variety of ways to suit your analysis needs.


ABOUT THE PROJECT

An airfoil (in American English) or aerofoil (in British English) is the shape of a wing or blade (of a propeller, rotor, or turbine) or sail as seen in cross-section. An airfoil-shaped body moved through a fluid produces an aerodynamic force. The component of this force perpendicular to the direction of motion is called lift. The component parallel to the direction of motion is called drag. Subsonic flight airfoils have a characteristic shape with a rounded leading edge, followed by a sharp trailing edge, often with asymmetric curvature of upper and lower surfaces. Foils of similar function designed with water as the working fluid are called hydrofoils. The lift on an airfoil is primarily the result of its angle of attack and shape. When oriented at a suitable angle, the airfoil deflects the oncoming air, resulting in a force on the airfoil in the direction opposite to the deflection. This force is known as aerodynamic force and can be resolved into two components: lift and drag. Most foil shapes require a positive angle of attack to generate lift, but cambered airfoils can generate lift at zero angle of attack. This "turning" of the air in the vicinity of the airfoil creates curved streamlines which results in lower pressure on one side and higher pressure on the other. This pressure difference is accompanied by a velocity difference, via Bernoulli's principle, so the resulting flow field about the airfoil has a higher average velocity on the upper surface than on the lower surface. The lift force can be related directly to the average top/bottom velocity difference without computing the pressure by using the concept of circulation and the KuttaJoukowski theorem.


Examples of airfoils in nature and within various vehicles. Thou gh not strictly an airfoil, the dolphin flipper obeys the same principles in a different fluid medium.

A fixed-wing aircraft's wings, horizontal, and vertical stabilizers are built with airfoil-shaped cross sections, as are helicopter rotor blades. Airfoils are also found in propellers, fans, compressors and turbines. Sails are also airfoils, and the underwater surfaces of sailboats, such as the centerboard and keel, are similar in cross-section and operate on the same principles as airfoils. Swimming and flying creatures and even many plants and sessile organisms employ airfoils/hydrofoils: common examples being bird wings, the bodies of fish, and the shape of sand dollars. An airfoil-shaped wing can create down force on an automobile or other motor vehicle, improving traction. Any object with an angle of attack in a moving fluid, such as a flat plate, a building, or the deck of a bridge, will generate an aerodynamic force (called lift)


perpendicular to the flow. Airfoils are more efficient lifting shapes, able to generate more lift (up to a point), and to generate lift with less drag. A lift and drag curve obtained in wind tunnel testing is shown on the right. The curve represents an airfoil with a positive camber so some lift is produced at zero angle of attack. With increased angle of attack, lift increases in a roughly linear relation, called the slope of the lift curve. At about 18 degrees this airfoil stalls, and lift falls off quickly beyond that. The drop in lift can be explained by the action of the upper-surface boundary layer, which separates and greatly thickens over the upper surface at and past the stall angle. The thickened boundary layer's displacement thickness changes the airfoil's effective shape in particular it reduces its effective camber, which modifies the overall flow field so as to reduce the circulation and the lift. The thicker boundary layer also causes a large increase in pressure drag, so that the overall drag increases sharply near and past the stall point. Airfoil design is a major facet of aerodynamics. Various airfoils serve different flight regimes. Asymmetric airfoils can generate lift at zero angle of attack, while a symmetric airfoil may better suit frequent inverted flight as in an aerobatic airplane. In the region of the ailerons and near a wingtip a symmetric airfoil can be used to increase the range of angles of attack to avoid spin – stall. Thus a large range of angles can be used without boundary layer separation. Subsonic airfoils have a round leading edge, which is naturally insensitive to the angle of attack. The cross section is not strictly circular, however: the radius of curvature is increased before the wing achieves maximum thickness to minimize the chance of boundary layer separation. This elongates the wing and moves the point of maximum thickness back from the leading edge.


Supersonic airfoils are much more angular in shape and can have a very sharp leading edge, which is very sensitive to angle of attack. A supercritical airfoil has its maximum thickness close to the leading edge to have a lot of length to slowly shock the supersonic flow back to subsonic speeds. Generally such transonic airfoils and also the supersonic airfoils have a low camber to reduce drag divergence. Modern aircraft wings may have different airfoil sections along the wing span, each one optimized for the conditions in each section of the wing. Movable high-lift devices, flaps and sometimes slats, are fitted to airfoils on almost every aircraft. A trailing edge flap acts similarly to an aileron; however, it, as opposed to an aileron, can be retracted partially into the wing if not used. A laminar flow wing has a maximum thickness in the middle camber line. Analyzing the Navier – Stokes equations in the linear regime shows that a negative pressure gradient along the flow has the same effect as reducing the speed. So with the maximum camber in the middle, maintaining a laminar flow over a larger percentage of the wing at a higher cruising speed is possible. However, with rain or insects on the wing, or for jetliner speeds, this does not work. Since such a wing stalls more easily, this airfoil is not used on wingtips (spin-stall again). Schemes have been devised to define airfoils – an example is the NACA system. Various airfoil generation systems are also used. An example of a general purpose airfoil that finds wide application, and predates the NACA system, is the Clark-Y. Today, airfoils can be designed for specific functions using inverse design programs such as PROFOIL, XFOIL and Aerofoil. XFOIL is an online program created by Mark Drela that will design and analyze subsonic isolated airfoils.


FLUENT AND STRUCTURAL ANALYSIS OF NACA 4515 AEROFOIL The NACA airfoils are airfoil shapes for aircraft wings developed by the National Advisory Committee for Aeronautics (NACA). The shape of the NACA airfoils is described using a series of digits following the word "NACA". The parameters in the numerical code can be entered into equations to precisely generate the crosssection of the airfoil and calculate its properties. The NACA four-digit wing sections define the profile by: 1. First digit describing maximum camber as percentage of the chord. 2. Second digit describing the distance of maximum camber from the airfoil leading edge in tens of percent of the chord. 3. Last two digits describing maximum thickness of the airfoil as percent of the chord. For example, the NACA 2412 airfoil has a maximum camber of 2% located 40% (0.4 chords) from the leading edge with a maximum thickness of 12% of the chord. Four-digit series airfoils by default have maximum thickness at 30% of the chord (0.3 chords) from the leading edge. The NACA 0015 airfoil is symmetrical, the 00 indicating that it has no camber. The 15 indicates that the airfoil has a 15% thickness to chord length ratio: it is 15% as thick as it is long .


AIRFOIL TERMINOLOGY

AIRFOIL NOMENCLATURE

The various terms related to airfoils are defined below: 

The suction surface (a.k.a. upper surface) is generally associated with higher velocity and lower static pressure.



The pressure surface (a.k.a. lower surface) has a comparatively higher static pressure than the suction surface. The pressure gradient between these two surfaces contributes to the lift force generated for a given airfoil.

The geometry of the airfoil is described with a variety of terms: 

The leading edge is the point at the front of the airfoil that has maximum curvature (minimum radius).



The trailing edge is defined similarly as the point of maximum curvature at the rear of the airfoil.



The chord line is the straight line connecting leading and trailing edges. The chord length, or simply chord , is the length of the chord line. That is the reference dimension of the airfoil section. CADD Centre Thiruvananthapuram | Ansys Workbench | 19

SCOPE OF THE PROJECT and PROBLEM DEFININTION

The Scope of this project is to design a 4515 aerofoil to work under extreme conditions without undergoing failure. To prove this, we need to analyze the aerofoil under a defined inlet velocity of 138 m/s in ANSYS FLUENT and a structural analysis is carried out to find whether it is structurally stable under the extreme conditions using ANSYS STRUCTURAL ANALYSIS . If the values obtained from analysis is safe hence the design can be used for practical application.

In this project, I am going to analyze fluid (air) flow over the NACA 4515 Aerofoil and its Structural Analysis.


APPROACH AND PROCEDURE

MODELING The coordinate text file is imported in the design modeler and 3D curve is generated using the coordinates given below Group Point 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 1 10 1 11 1 12 1 13 1 14 1 15 1 16 1 17 1 18 1 19 1 20 1 21 1 22 1 23 1 24 1 25 1 26 1 27 1 28 1 29 1 30 1 31 1 32 1 33 1 34 1 35 1 36

X_cord 1.00000 0.99893 0.99572 0.99039 0.98296 0.97347 0.96194 0.94844 0.93301 0.91573 0.89668 0.87592 0.85355 0.82967 0.80438 0.77779 0.75000 0.72114 0.69134 0.66072 0.62941 0.59755 0.56526 0.53270 0.50000 0.46730 0.43474 0.40245 0.37059 0.33928 0.30866 0.27886 0.25000 0.22221 0.19562 0.17033

Y-cord 0.00000 0.00039 0.00156 0.00349 0.00610 0.00932 0.01303 0.01716 0.02166 0.02652 0.03171 0.03717 0.04283 0.04863 0.05453 0.06048 0.06642 0.07227 0.07795 0.08341 0.08858 0.09341 0.09785 0.10185 0.10538 0.10837 0.11076 0.11248 0.11345 0.11361 0.11294 0.11141 0.10903 0.10584 0.10190 0.09726

Z-cord 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0


1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

37 38 39 40 41 42 43 44 45 46 47 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82

0.14645 0.09195 0.12408 0.08607 0 0.10332 0.07970 0 0.08427 0.07283 0 0.06699 0.06541 0 0.05156 0.05753 0 0.03806 0.04937 0 0.02653 0.04118 0 0.01704 0.03303 0 0.00961 0.02489 0 0.00428 0.01654 0 0.00107 0.00825 0 0.00000 0.00075 0 0.00107 -0.00566 0 0.00428 -0.01102 0 0.00961 -0.01590 0 0.01704 -0.02061 0 0.02653 -0.02502 0 0.03806 -0.02915 0 0.05156 -0.03281 0 0.06699 -0.03582 0 0.08427 -0.03817 0 0.10332 -0.03991 0 0.12408 -0.04106 0 0.14645 -0.04166 0 0.17033 -0.04177 0 0.19562 -0.04147 0 0.22221 -0.04078 0 0.25000 -0.03974 0 0.27886 -0.03845 0 0.30866 -0.03700 0 0.33928 -0.03547 0 0.37059 -0.03390 0 0.40245 -0.03229 0 0.43474 -0.03063 0 0.46730 -0.02891 0 0.50000 -0.02713 0 0.53270 -0.02529 0 0.56526 -0.02340 0 0.59755 -0.02149 0 0.62941 -0.01958 0 0.66072 -0.01772 0 0.69134 -0.01596 0 0.72114 -0.01430 0 0.75000 -0.01277 0

0


1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

83 84 85 86 87 88 89 90 91 92 93 94 95 96 97

0.77779 0.80438 0.82967 0.85355 0.87592 0.89668 0.91573 0.93301 0.94844 0.96194 0.97347 0.98296 0.99039 0.99572 0.99893

-0.01136 -0.01006 -0.00886 -0.00775 -0.00674 -0.00583 -0.00502 -0.00431 -0.00364 -0.00297 -0.00227 -0.00156 -0.00092 -0.00042 -0.00011

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

MATERIAL PROPERTY Material 1 – Air Isentropic Relative Permeability of air =1 Material 2 – Aluminum alloy Properties of aluminum alloy: -3

Density = 2770 kg m

9

Young's Modulus = 71x 10 Pa Poisson's Ratio = 0.33 7

Tensile Yield Strength = 28x10 Pa 7

Tensile Ultimate Strength = 31x10 Pa 1

-1

Specific Heat = 875 J kg- C


MESHING

The Blue colour surface indicates Air Inlet The Red colour surface indicates Air Outlet The White colour body indicates the Aerofoil The remaining four yellow colour surfaces are symmetrical and acts as a wall


Fig 1

Fig 1 shows the meshing of whole body i.e. the aerofoil and the close surface.


Fig 2

Fig 2 represents the closer view of meshed Aerofoil.

Total no. of nodes = 96477 Total no. of elements = 543160


Details of meshing


BOUNDARY CONDITIONS FOR FLUENT 





The front surface is assumed as the Velocity inlet and the rear surface is assumed as the pressure outlet. The inlet velocity of air is defined as 138 m/s and the pressure at the exit is set as 0 Pascal. Number of iterations is set as 100

FOR STATIC STRUCTURAL ANALYSIS

1. Fixed support

The Scoping method is changed to Named selection from geometry selection. Fixed support is assigned to the Connection face of Wing.


2. Fluid Solid Interface



RESULTS

FLUENT


Contour option is selected from the Fluent window and the left surface is selected from the pop up window. Display tab is clicked for the result. And the contours of static pressure are observed.


A plane is created with co-ordinates X1= 0

y1=0

z1= -5

X2= 5

y2=0

z1= -5

X3= 0

y1= 5

z1= -5

And the contours of static pressure are observed.



y1=0

z1= -7

X2= 5

y2=0

z1= -7

X3= 0

y1= 5

z1= -7




y1=0

z1= -8

X2= 5

y2=0

z1= -8

X3= 0

y1= 5

z1= -8



Isometric View of the Aerofoil. The contours of static pressure are observed. The static pressure has low values as it extends from left to ri ht from the to surface of the aerofoil.


Isometric View 2 of the Aerofoil. The contours of static pressure are observed. The static pressure has maximum value at the bottom surface of the aerofoil.


Vectors option is selected from the Fluent window and the left surface is selected from the pop up window. Display tab is clicked for the result. And the velocity vectors colored by Velocity magnitude (m/s) are observed.



y1=0

z1= -5

X2= 5

y2=0

z1= -5

X3= 0

y1= 5

z1= -5

And the velocity vectors colored by Velocity magnitude in m/s are observed.



y1=0

z1= -7

X2= 5

y2=0

z1= -7

X3= 0

y1= 5

z1= -7

And the velocity vectors colored by Velocity magnitude in m/s are observed.


STRUCTURAL First Saved Monday, October 13, 2014 Last Saved Monday, October 13, 2014 Product Version 14.0 Release Save Project Before Solution No Save Project After Solution No

TABLE 1


Unit System Metric (m, kg, N, s, V, A) Degrees rad/s Celsius Angle Degrees Rotational Velocity rad/s Temperature Celsius

Model (C4) Geometry

Object Name State Source Type Length Unit Element Control Display Style Length X Length Y Length Z Volume Mass Scale Factor Value Bodies Active Bodies Nodes Elements Mesh Metric Parameters Parameter Key Attributes Named Selections Material Properties Use Associativity Coordinate Systems Reader Mode Saves Updated File Use Instances Smart CAD Update Attach File Via Temp File Temporary Directory

TABLE 2 Model (C4) > Geometry Geometry Fully Defined Definition E:\ANSYS WORKBENCH\Nithin Devasia\ANSYS Project\CFD and Structural Analysis of NACA 4415 Aerofoil_files \dp0\Geom\DM\Geom.agdb DesignModeler Millimeters Program Controlled Body Color Bounding Box 17.324 m 8.5843 m 10. m Properties 0.12124 m³ 335.83 kg 1. Statistics 2 1 76553 39122 None Basic Geometry Options Yes DS No No No Advanced Geometry Options Yes No No Yes No Yes C:\Users\SDA\AppData\Roam ing\Ansys\v140


Analysis Type Decompose Disjoint Faces Enclosure and Symmetry Processing

3-D Yes Yes

TABLE 3 Model (C4) > Geometry > Parts WING AIR Object Name State Meshed Suppressed Graphics Properties Visible Yes No Transparency 1 Definition Suppressed No Yes Stiffness Behavior Flexible Coordinate System Default Coordinate System Reference Temperature By Environment Material Assignment Aluminum Alloy Structural Steel Nonlinear Effects Yes Thermal Strain Effects Yes Bounding Box Length X 1.8088 m 17.324 m Length Y 0.34196 m 8.5843 m Length Z 7. m 10. m Properties Volume 0.12124 m³ 1484.7 m³ Mass 335.83 kg 1.1655e+007 kg Centroid X 0.84176 m 0.32265 m Centroid Y -2.9072e-002 m 0.4867 m Centroid Z -3.4821 m -5.0024 m Moment of Inertia Ip1 1686.2 kg·m² 1.6885e+008 kg·m² Moment of Inertia Ip2 1782.8 kg·m² 3.8912e+008 kg·m² Moment of Inertia Ip3 103.51 kg·m² 3.6364e+008 kg·m² Statistics Nodes 76553 0 Elements 39122 0 Mesh Metric None

Coordinate Systems


TABLE 4 Model (C4) > Coordinate Systems > Coordinate System Object Name Global Coordinate System State Fully Defined Definition Type Cartesian Coordinate System ID 0. Origin Origin X 0. m Origin Y 0. m Origin Z 0. m Directional Vectors X Axis Data [ 1. 0. 0. ] Y Axis Data [ 0. 1. 0. ] Z Axis Data [ 0. 0. 1. ]

Connections TABLE 5 Model (C4) > Connections Object Name Connections State Fully Defined Auto Detection Generate Automatic Connection On Refresh Yes Transparency Enabled Yes TABLE 6 Model (C4) > Connections > Contacts Contacts Object Name State Suppressed Definition Connection Type Contact Scope Scoping Method Geometry Selection Geometry All Bodies Auto Detection Tolerance Type Slider Tolerance Slider 0. Tolerance Value 5.4418e-002 m Use Range No Face/Face Yes Face/Edge No Edge/Edge No Priority Include All Group By Bodies Search Across Bodies TABLE 7 Model (C4) > Connections > Contacts > Contact Regions


Contact Region Object Name State Suppressed Scope Scoping Method Geometry Selection Contact 5 Faces Target No Selection Contact Bodies WING Target Bodies AIR Definition Type Bonded Scope Mode Automatic Behavior Program Controlled Suppressed No Advanced Formulation Program Controlled Detection Method Program Controlled Normal Stiffness Program Controlled Update Stiffness Program Controlled Pinball Region Program Controlled

Mesh TABLE 8 Model (C4) > Mesh Object Name Mesh State Solved Defaults Physics Preference Mechanical Relevance 0 Sizing Use Advanced Size Function Off Relevance Center Coarse Element Size Default Initial Size Seed Active Assembly Smoothing Medium Transition Fast Span Angle Center Coarse Minimum Edge Length 5.e-003 m Inflation Use Automatic Inflation None Inflation Option Smooth Transition Transition Ratio 0.272 Maximum Layers 5 Growth Rate 1.2 Inflation Algorithm Pre View Advanced Options No Patch Conforming Options Triangle Surface Mesher Program Controlled Advanced


Shape Checking Standard Mechanical Element Midside Nodes Program Controlled Straight Sided Elements No Number of Retries Default (4) Extra Retries For Assembly Yes Rigid Body Behavior Dimensionally Reduced Mesh Morphing Disabled Defeaturing Pinch Tolerance Please Define Generate Pinch on Refresh No Automatic Mesh Based Defeaturing On Defeaturing Tolerance Default Statistics Nodes 76553 Elements 39122 Mesh Metric None

Named Selections TABLE 9 Model (C4) > Named Selections > Named Selections Object Name ConnectionFaceofWing WingPeripherals Aircontcatsurafce AirInlet AirOutlet State Fully Defined Suppressed Scope Scoping Method Geometry Selection Geometry 1 Face 3 Faces No Selection Definition Send to Solver Yes Visible Yes Program Controlled Exclude Inflation Statistics Type Imported Total Selection 1 Face 3 Faces 1 Face Suppressed 0 3 1 Used by Mesh Worksheet No TABLE 10 Model (C4) > Named Selections > Named Selections Object Name LeftSurface Toprightbottomsurfaces State Suppressed Scope Scoping Method Geometry Selection Geometry No Selection Definition Send to Solver Yes Visible Yes Program Controlled Inflation Exclude Statistics Type Imported


Total Selection Suppressed Used by Mesh Worksheet

1 Face 1

3 Faces 3 No

Static Structural (C5) TABLE 11 Model (C4) > Analysis Object Name Static Structural (C5) State Solved Definition Physics Type Structural Analysis Type Static Structural Solver Target Mechanical APDL Options Environment Temperature 22. °C Generate Input Only No

Object Name State Restart Type Status Number Of Steps Current Step Number Step End Time Auto Time Stepping Solver Type Weak Springs Large Deflection Inertia Relief Generate Restart Points Retain Files After Full Solve Force Convergence Moment Convergence Displacement Convergence Rotation Convergence Line Search Stabilization

TABLE 12 Model (C4) > Static Structural (C5) > Analysis Settings Analysis Settings Fully Defined Restart Analysis Program Controlled Done Step Controls 1. 1. 1. s Program Controlled Solver Controls Program Controlled Program Controlled Off Off Restart Controls Program Controlled Yes Nonlinear Controls Program Controlled Program Controlled Program Controlled Program Controlled Program Controlled Off


Output Controls Stress Strain Nodal Forces Contact Miscellaneous General Miscellaneous Calculate Results At Max Number of Result Sets Solver Files Directory Future Analysis Scratch Solver Files Directory Save MAPDL db Delete Unneeded Files Nonlinear Solution Solver Units Solver Unit System

Yes Yes No No No All Time Points Program Controlled Analysis Data Management E:\ANSYS WORKBENCH\Nithin Devasia\ANSYS Project\CFD and Structural Analysis of NACA 4415 Aerofoil_fil es\dp0\SYS\MECH\ None

No Yes No Active System mks

TABLE 13 Model (C4) > Static Structural (C5) > Loads Fixed Support Fluid Solid Interface Object Name State Fully Defined Scope Scoping Method Named Selection Named Selection ConnectionFaceofWing WingPeripherals Definition Type Fixed Support Fluid Solid Interface Suppressed No Interface Number 1.

Solution (C6) TABLE 14 Model (C4) > Static Structural (C5) > Solution Object Name Solution (C6) State Solved Adaptive Mesh Refinement Max Refinement Loops 1. Refinement Depth 2. Information Status Done

TABLE 15


Model (C4) > Static Structural (C5) > Solution (C6) > Solution Information

Object Name Solution Information State Solved Solution Information Solution Output Solver Output Newton-Raphson Residuals 0 Update Interval 2.5 s Display Points All FE Connection Visibility Activate Visibility Yes Display All FE Connectors Draw Connections Attached To All Nodes Line Color Connection Type Visible on Results No Line Thickness Single Display Type Lines

Object Name State Scoping Method Geometry Type By Display Time Calculate Time History Identifier Suppressed Display Option Minimum Maximum Time Load Step Substep Iteration Number

TABLE 16 Model (C4) > Static Structural (C5) > Solution (C6) > Results Maximum Principal Minimum Principal Equivalent Stress Stress Stress Solved Scope Geometry Selection 1 Face All Bodies Definition Equivalent (von-Mises) Maximum Principal Minimum Principal Stress Stress Stress Time Last

Total Deformation

Total Deformation

Yes No Integration Point Results Averaged Results 31980 Pa -7.1972e+007 Pa 2.6611e+008 Pa 4.2613e+008 Pa Information 1. s 1 1 5

-3.9676e+008 Pa 1.2876e+008 Pa

0. m 0.41933 m


FIGURE 1 Model (C4) > Static Structural (C5) > Solution (C6) > Equivalent Stress > Image


FIGURE 2 Model (C4) > Static Structural (C5) > Solution (C6) > Maximum Principal Stress > Image


FIGURE 3 Model (C4) > Static Structural (C5) > Solution (C6) > Minimum Principal Stress > Image


FIGURE 4 Model (C4) > Static Structural (C5) > Solution (C6) > Total Deformation > Image


TABLE 17

Model (C4) > Static Structural (C5) > Solution (C6) > Probes

Object Name Force Reaction Moment Reaction State Solved Definition Type Force Reaction Moment Reaction Location Method Boundary Condition Boundary Condition Fixed Support Orientation Global Coordinate System Suppressed No Summation Centroid Options Result Selection All Display Time End Time Results X Axis -4909.8 N -4.1227e+005 N·m Y Axis -1.2853e+005 N 19599 N·m Z Axis 1530.7 N 19913 N·m Total 1.2863e+005 N 4.1322e+005 N·m Maximum Value Over Time X Axis -4909.8 N -4.1227e+005 N·m Y Axis -1.2853e+005 N 19599 N·m Z Axis 1530.7 N 19913 N·m Total 1.2863e+005 N 4.1322e+005 N·m Minimum Value Over Time X Axis -4909.8 N -4.1227e+005 N·m Y Axis -1.2853e+005 N 19599 N·m Z Axis 1530.7 N 19913 N·m Total 1.2863e+005 N 4.1322e+005 N·m Information Time 1. s Load Step 1 Substep 1 Iteration Number 5


FIGURE 5

Model (C4) > Static Structural (C5) > Solution (C6) > Force Reaction > Image


FIGURE 6

Model (C4) > Static Structural (C5) > Solution (C6) > Moment Reaction > Image

Material Data Aluminum Alloy TABLE 18 Aluminum Alloy > Constants Density 2770 kg m^-3 Coefficient of Thermal Expansion 2.3e-005 C^-1 Specific Heat 875 J kg^-1 C^-1 TABLE 19 Aluminum Alloy > Compressive Ultimate Strength Compressive Ultimate Strength Pa 0


TABLE 20 Aluminum Alloy > Compressive Yield Strength Compressive Yield Strength Pa 2.8e+008 TABLE 21 Aluminum Alloy > Tensile Yield Strength Tensile Yield Strength Pa 2.8e+008 TABLE 22 Aluminum Alloy > Tensile Ultimate Strength Tensile Ultimate Strength Pa 3.1e+008 TABLE 23 Aluminum Alloy > Isotropic Secant Coefficient of Thermal Expansion Reference Temperature C 22 TABLE 24 Aluminum Alloy > Isotropic Thermal Conductivity Thermal Conductivity W m^-1 C^-1 Temperature C 114 -100 144 0 165 100 175 200 TABLE 25 Aluminum Alloy > Alternating Stress R-Ratio Alternating Stress Pa Cycles R-Ratio 2.758e+008 1700 -1 2.413e+008 5000 -1 2.068e+008 34000 -1 1.724e+008 1.4e+005 -1 1.379e+008 8.e+005 -1 1.172e+008 2.4e+006 -1 8.963e+007 5.5e+007 -1 8.274e+007 1.e+008 -1 1.706e+008 50000 -0.5 1.396e+008 3.5e+005 -0.5 1.086e+008 3.7e+006 -0.5 8.791e+007 1.4e+007 -0.5 7.757e+007 5.e+007 -0.5 7.239e+007 1.e+008 -0.5 1.448e+008 50000 0 1.207e+008 1.9e+005 0 1.034e+008 1.3e+006 0 9.308e+007 4.4e+006 0


8.618e+007 7.239e+007 7.412e+007 7.067e+007 6.636e+007 6.205e+007

1.2e+007 1.e+008 3.e+005 1.5e+006 1.2e+007 1.e+008

0 0 0.5 0.5 0.5 0.5

TABLE 26 Aluminum Alloy > Isotropic Resistivity Resistivity ohm m Temperature C 2.43e-008 0 2.67e-008 20 3.63e-008 100 TABLE 27 Aluminum Alloy > Isotropic Elasticity Temperature C Young's Modulus Pa Poisson's Ratio Bulk Modulus Pa Shear Modulus Pa 7.1e+010 0.33 6.9608e+010 2.6692e+010 TABLE 28 Aluminum Alloy > Isotropic Relative Permeability Relative Permeability 1

Structural Steel TABLE 29 Structural Steel > Constants Density 7850 kg m^-3 Coefficient of Thermal Expansion 1.2e-005 C^-1 Specific Heat 434 J kg^-1 C^-1 Thermal Conductivity 60.5 W m^-1 C^-1 Resistivity 1.7e-007 ohm m TABLE 30 Structural Steel > Compressive Ultimate Strength Compressive Ultimate Strength Pa 0 TABLE 31 Structural Steel > Compressive Yield Strength Compressive Yield Strength Pa 2.5e+008 TABLE 32 Structural Steel > Tensile Yield Strength Tensile Yield Strength Pa 2.5e+008


TABLE 33 Structural Steel > Tensile Ultimate Strength Tensile Ultimate Strength Pa 4.6e+008 TABLE 34 Structural Steel > Isotropic Secant Coefficient of Thermal Expansion Reference Temperature C 22 TABLE 35 Structural Steel > Alternating Stress Mean Stress Alternating Stress Pa Cycles Mean Stress Pa 3.999e+009 10 0 2.827e+009 20 0 1.896e+009 50 0 1.413e+009 100 0 1.069e+009 200 0 4.41e+008 2000 0 2.62e+008 10000 0 2.14e+008 20000 0 1.38e+008 1.e+005 0 1.14e+008 2.e+005 0 8.62e+007 1.e+006 0

Strength Coefficient Pa 9.2e+008

TABLE 36 Structural Steel > Strain-Life Parameters Strength Ductility Ductility Cyclic Strength Cyclic Strain Exponent Coefficient Exponent Coefficient Pa Hardening Exponent -0.106 0.213 -0.47 1.e+009 0.2

TABLE 37 Structural Steel > Isotropic Elasticity Temperature C Young's Modulus Pa Poisson's Ratio Bulk Modulus Pa Shear Modulus Pa 2.e+011 0.3 1.6667e+011 7.6923e+010 TABLE 38

Structural Steel > Isotropic Relative Permeability

Relative Permeability 10000


INFERENCE

From the Fluid flow analysis it is observed that the maximum value of static pressure which is exerted by the air on the surface of the aerofoil is 12600 Pascal and the maximum magnitude of velocity of air leaving from the surface of aerofoil is found to be 235 m/s. So according to the protocols of National Advisory Committee for Aeronautics, the value of Static pressure and Magnitude of velocity are under the permissible limits and hence the design is fluid dynamically safe, hence for finding out the structural stability of the design, a static structural analysis coupled with Workbench system coupling is conducted and the values of Equivalent stress, Maximum and Minimum Principal Stress, Total deformation, Force and Moment reactions are obtained. The maximum value of Von misses stress is found out to be 266.11 MPa, Maximum principal stress is 426.13 MPa, Minimum principal stress is 128.76 MPa and Maximum deformation is 419.33 mm. The above obtained values are within the desired limits according to National Advisory Committee for Aeronautics (NACA), hence the design is structurally safe.


SUGGESTIONS AND CONCLUSIONS

The fluid flow and structural analysis can be carried out for a different value of the inlet air velocity and the angle of attack and camber angle may be changed in order to get different result.

Fluid flow and Structural analysis of NACA 4515 Aerofoil is carried out with Ansys Workbench and the required results are obtained. The results are found successful and the aerofoil can be used for practical application.


Project Report AnSys Workbench - Nithin L Devasia

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