Mukesh Reddy - 1DS17AE018 EDX

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DAYANANDA SAGAR COLLEGE OF ENGINEERING

(An autonomous Institute affiliated to Visvesvaraya Technological University, approved by AICTE &
UGC, Accredited by NAAC with 'A' grade and ISO 9001-2015 Certified Institution)
DEPARTMENT OF AERONAUTICAL ENGINEERING
(Accredited by National Board of Accreditation, NBA)

A MOOCs course Report on

“A HANDS-ON INTRODUCTION TO ENGINEERING


SIMULATION”
(Sub Code: 17AE8ICHSS)

Submitted in partial fulfillment for the award of the degree


BACHELOR OF ENGINEERING
in
AERONAUTICAL ENGINEERING.

Submitted By
Kallamkunta Mukesh Reddy (1DS17AE018)

2020-2021

Under the guidance of


Prof V Yamini Anoosha
Assistant Prof, Department of Aeronautical Engg.
Dayananda Sagar College of Engineering
Bengaluru-560078
DAYANANDA SAGAR COLLEGE OF ENGINEERING
(An autonomous Institute affiliated to Visvesvaraya Technological University, approved by AICTE &
UGC, Accredited by NAAC with 'A' grade and ISO 9001-2015 Certified Institution)
DEPARTMENT OF AERONAUTICAL ENGINEERING
(Accredited by National Board of Accreditation, NBA)

CERTIFICATE

Certified that the MOOCs Course entitled “A Hands-on Introduction to


Engineering Simulation” carried out by Mr. Kallamkunta Mukesh Reddy
(1DS17AE018)in partial fulfillment for the award of Bachelor of
Engineering in Aeronautical Engineering, during the academic year 2020-
21. It is certified that all corrections/suggestions indicated for internal
assessment have been incorporated in the report deposited in the
departmental library. The report has been approved as it satisfies the
academic requirements in respect of project work prescribed for the said
degree.

Signature of the Guide Signature of the HOD Signature of the


(V Yamini Anoosha) (Dr. Hareesha N G) Principal
(Dr. C P S Prakash)
CERTIFICATE
DECLARATION
I, KALLAMKUNTA MUKESH REDDY (1DS17AE018) hereby declare that, this
MOOCS COURSE work entitled “A Hands-on Introduction to Engineering Simulation”
has been carried out by me under the guidance of V Yamini Anoosha, Assistant Prof,
Department Of Aeronautical Engineering, in partial fulfilment of the requirement of the
degree Bachelor of Engineering in Aeronautical Engineering.

Place: Bangalore Kallamkunta Mukesh Reddy


Date: (1DS17AE018)

IV
ACKNOWLEDGEMENT

Before introducing our thesis work, we would like to thank the people without
whom the success of this thesis would have been only a dream.
We express our deep sense of gratitude and indebtedness to V Yamini Anoosha,
Assistant Prof, Department of Aeronautical Engineering, for his valuable guidance,
continuous assistance and in the critical appraisal of the thesis.
We express our sincere thanks to Dr. Hareesha N G, Professor and HOD,
Department of Aeronautical Engineering, for providing the facilities required for the
completion of this project work.
It is with great pleasure, we extend our gratitude and thanks to Dr.C P S Prakash,
Principal, Dayananda Sagar College of Engineering, for his encouragement throughout
the project.
We are also thankful to V Yamini Anoosha, MOOCS/SWACHH BRARAT
coordinator, Department of Aeronautical Engineering for his encouragement in
successfully completing this project work.
We feel short words to express our heartfelt thanks to all our family members and
friends and all those who have directly or indirectly helped me during our course.]

Kallamkunta Mukesh Reddy (1DS17AE018)

V
ABSTRACT

The capacity of a traditional classroom to accommodate a large number of students


is limited, but millions of people throughout the world desire and require high-quality
education. Massive open online courses, or MOOCs, are a type of online course. The idea,
which was pioneered by edX, began as a way for organisations to provide free online
courses to millions of students all over the world. edX's 'A Hands-on Introduction to
Engineering Simulation' is one such MOOC that has been finished.
Engineering Simulation is the imitative representation of the functioning of one
system (e.g. mechanical, electrical, digital, etc.) or process by means of the functioning of
another. We may be concerned with simulation of the functioning of mechanical and
structural components by mathematical models. A software named ANSYS was used for
the same. Ansys, Inc. is an American company based in Canonsburg, Pennsylvania. It
develops and markets CAD/CAM and Multiphysics engineering simulation software for
product design, testing and operation and offers its products and services to customers
worldwide.
Understanding what's under the blackbox will be the focus in order to move beyond
garbage-in, garbage-out. We practise solving issues including structural mechanics, fluid
dynamics, and heat transfer utilising a common solution approach. To grasp the
fundamental principles of finite-element analysis and computational fluid dynamics, we
solve textbook cases. Then, using these ideas, we'll use the programme to replicate real-
world examples like a bolted rocket assembly and a wind turbine rotor.

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TABLE OF CONTENTS
Certificate II
Course Certificate III
Declaration IV
Acknowledgement V
Abstract VI
List of Figures VIII
CHAPTER - 1 10
INTRODUCTION 10
1.1 Introduction 10
1.1.1 MOOC Courses 10
1.1.2 Engineering Simulation 12
CHAPTER - 2 12
MOOC RESOURCES 12
2.1 edX 12
2.1.1 Cornell University 12
2.2 About this course 12
Chapter - 3 14
Course work 14
3.1 Course Objectives 14
3.2 Course Modules 14
3.2.1 Module 1: Finite Element Analysis (FEA) 14
3.2.2 Module 2: Finite Element Analysis (FEA) (Solid Mechanics) 16
3.2.3 Module 3: Finite Element Analysis (FEA) (Bolted Nozzle Flange) 18
3.2.4 Module 4: Computational Fluid Dynamics (CFD) 20
3.3 Course Assignments 22
Chapter - 4 23
Conclusion 23
4.1 Conclusion 23

VII
LIST OF FIGURES
S.No Description Page No.
Figure 3.2.1 2D Conduction Problem 16

Figure 3.2.2 Bike Crank 17

Figure 3.2.3 Saturn V rocket booster 18

Figure 3.2.4 Ansys geometry of booster 19

Figure 3.2.5 Close-up bolt assembly 19

Figure 3.2.6 Pipe 21

Figure 3.3.1 Grade summary 22

VIII
LIST OF ABBREVIATIONS

Acc Accuracy
ANOVA Analysis Of Variance
Ao Cost of replacement or repair
CNC Computer Numerical Control
DOE Design Of Experiments
DOF Degrees Of Freedom

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A Hands-on Introduction to Engineering Simulation

CHAPTER 1

INTRODUCTION

1.1 INTRODUCTION

1.1.1 MOOC COURSES

Learning is undergoing a transformation. MOOCs have become ubiquitous in our


daily lives in recent years, allowing everyone, regardless of nation or degree of education,
to learn about a variety of topics. MOOCs are increasingly a viable alternative to traditional
training, whether for personal motivation or to enhance a student's CV. They enable us to
train at our own pace, from any location, and at a reduced cost.
The idea for this online learning approach came from prominent American
universities like Harvard and MIT. MOOCs have made it feasible to gain access to
knowledge from some of the world's most prominent universities.
Massive Open Online Courses, or MOOCs, are an acronym for Massive Open
Online Courses. This means that these courses, which are offered by schools, universities,
and corporations, are available for free on the Internet to anybody. MOOCs are free and
open to the public, bringing together thousands of people. MOOCs offer the advantage of
fostering considerable interactivity between learners, as well as stakeholders, over e-
learning and simple tutorials.
After following a MOOC and fulfilling the expectations of the teaching team
(results in quizzes, projects/assignments, peer evaluations), you will obtain a certificate of
achievement. Be aware, however, that once registered, there is no obligation to finish a
MOOC if it does not meet your expectations, or seems too difficult.

1.1.2 ENGINEERING SIMULATION

Simulation engineering is a broad term used to describe computer simulation


technologies and programs used to model engineering projects and evaluate the risks and
benefits in a virtual environment. The use of these types of programs has expanded
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A Hands-on Introduction to Engineering Simulation

exponentially in the past 10 years, allowing engineering advances in every area, ranging
from bioengineering to environmental science. There are four main components to
simulation engineering: software, memory requirements, hardware resources, and user
interfaces.
All simulation engineering tools are designed for use by trained engineers or
engineering technologists. Many engineering post-secondary programs now have courses
in simulation engineering, when it should be used, and how to interpret the results. This
advance in technology has greatly reduced costly errors, allows engineering research to
expand into new areas at a much lower cost, and to work out the landscape of their research
before actually starting the physical project. The software used in simulation engineering
is specifically designed for each discipline. The quality and flexibility of these programs
have increased dramatically with expanded usage. As such, the software products available
now include time lapse and projections, impact of natural forces over extended time frames,
and the impact of temperature fluctuations.
The sheer amount of memory and system resources necessary to employ simulation
engineering software is one of the remaining roadblocks. It's worth noting that the
improvement was not due to a change in the requirements, but rather to better processing
and communication. Memory has become more affordable, allowing this business to grow.
As far as computers go, Memory makers have improved their procedures, which has
resulted in lower costs. According to them, according to Moore's law, the cost of memory
should reduce by 50% every 18 months.
Hardware requirements for these software products are significant. In the interest
of cost savings, many large research universities combine resources and funding to create
separate institutes for engineering research. These institutes function independently, but are
responsible to a board of directors representing all the partner institutes. As such, the
research is able to progress, and the knowledge shared. This type of partnership is not
uncommon in the post-secondary sector, but is not viable in the private sector.
User interfaces required for simulation engineering have advanced in the past few
years. Traditionally, users were required to learn programming languages, and key in all
the specifications and requirements. The computer would process the request and provide
the results of the calculations. Advances in technology and resource allocation now allow
users to have graphical interfaces, multidimensional projections, and view the impact of
specific actions on the shape and other physical characteristics.

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A Hands-on Introduction to Engineering Simulation

CHAPTER 2

MOOC RESOURCES

2.1 EDX

edX is a massive open online course (MOOC) provider founded by Harvard and
MIT in the United States. It offers online university-level courses in a variety of fields to a
global student base, with some courses available for free. It also performs learning research
depending on how users interact with its platform. edX is a non-profit organisation that
uses the open-source Open edX software platform. On June 29th, 2021, it was reported that
edX had been purchased by 2U, a business that specialises in educational technology. More
than 150 schools, non-profit organizations, and corporations offer or plan to offer courses
on the edX website. As of 20 July 2020, edX has around 33 million students taking more
than 3,000 courses online. edX also has over 6,000 instructors on the platform with a
presence of 196 countries represented worldwide. Vanderbilt University.
The MOOC ‘A Hands-on Introduction to Engineering Simulation’ which was
completed on the online MOOC platform edX was offered by the Cornell University.

2.1.1 CORNELL UNIVERSITY

Cornell University is a community of scholars distinguished for intellectual rigor


and involved in deep and extensive research, teaching tomorrow's thought leaders to think
differently, care for others, and lead by example generate and distribute knowledge for the
benefit of the public Once referred to as "the initial university in the United States "Cornell
is a symbol of education, according to Frederick Rudolph, an educational historian a unique
blend of illustrious knowledge and democratic principles.

2.2 ABOUT THIS COURSE

We learned how to do engineering simulations using a powerful tool from ANSYS,


Inc. in this hands-on training. This is a problem-based course in which we will learn by
doing. The focus will be on understanding what's under the Blackbox so as to move beyond

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A Hands-on Introduction to Engineering Simulation

garbage-in, garbage-out. We practiced using a common solution approach to problems


involving different physics: structural mechanics, fluid dynamics and heat transfer.
To grasp the fundamental principles of finite-element analysis and computational
fluid dynamics, we solved textbook cases. Then, using these concepts, we used the program
to mimic real-world scenarios, including a mounted rocket. A wind turbine rotor, and a
wind turbine assembly We also talked about current industry practices. A n engineer for
SpaceX by using a leading simulation tool to work through examples, we learned to think
like an engineer instead of hitting buttons, like professionals do. This course teaches
fundamental concepts and tool use in an integrated fashion using the power of online
learning.

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A Hands-on Introduction to Engineering Simulation

CHAPTER 3

COURSE WORK

3.1 COURSE OBJECTIVES

• Big ideas in finite-element analysis and computational fluid dynamics

• Fluid dynamics simulations using ANSYS Fluent™

• Structural mechanics simulations using ANSYS Mechanical™

• Mathematical models underlying simulations

• Building simulations of real-world applications using ANSYS® software

• Verification and validation of simulations including checking against hand calculations

• How to approach engineering analysis and simulations like an expert

3.2 COURSE MODULES

3.2.1 MODULE1 : FINITE ELEMENT ANALYSIS (FEA)

Finite Element Analysis or FEA is the simulation of a physical phenomenon using


a numerical mathematic technique referred to as the Finite Element Method, or FEM. This
process is at the core of mechanical engineering, as well as a variety of other disciplines. It
also is one of the key principles used in the development of simulation software. Engineers
can use these FEM to reduce the number of physical prototypes and run virtual experiments
to optimize their designs.
Complex mathematics is required in order to understand the physical phenomena
that occur all around us. These include things like fluid dynamics, wave propagation, and
thermal analysis.
Analysing most of these phenomena can be done using partial differential
equations, but in complex situations where multiple highly variable equations are needed,
Finite Element Analysis is the leading mathematical technique.

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A Hands-on Introduction to Engineering Simulation

The problem can be divided into this following specification:


1. Pre- Analysis
2. Geometry
3. Mesh
4. Model Setup
5. Numerical Solution
6. Numerical Results
7. Verification and Validation

Summary of the Big Ideas: Finite Element Analysis –

• Reduce the problem to solving selected variable(s) at selected locations (nodes)


• Mathematical model to be solved is usually a boundary value problem
• Assume a shape for selected variable(s) within each element
• Derive system of algebraic equations relating neighbouring nodal values
• Invert this system to determine selected variable(s) at nodes
• Derive everything else from selected variable(s) at nodes
• Reduce error by using more elements and/or increasing the order of interpolation
• Finite-element solution doesn’t satisfy the differential equation(s)
• Satisfies a special weighted integral form
• Essential boundary conditions are satisfied exactly
• Natural or gradient boundary conditions are satisfied approximately

2D Conduction Problem –
• Develop the solution to a 2D heat conduction problem in ANSYS Mechanical
• Verify the numerical results from ANSYS
• Connect the ANSYS steps to concepts covered in the Big Ideas: Finite Element Analysis
section

Figure 3.2.1 shows the 2D Conduction problem that was required to be solved using
ANSYS workbench.

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A Hands-on Introduction to Engineering Simulation

Figure 3.2.1 - 2D Conduction Problem


The problem was solved following the problem specifications as show above. The
ANSYS results was compared and validated with hand calculation of the heat flux for the
given problem.

3.2.2 MODULE 2 : FINITE ELEMENT ANALYSIS (FEA) (SOLID MECHANICS)

In this module, we learnt to:

• Develop the solution to a 3D structural mechanics problem in ANSYS Mechanical


• Verify and validate the numerical results from ANSYS
• Connect the ANSYS steps to concepts covered in the Big Ideas: Finite Element
Analysis section

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A Hands-on Introduction to Engineering Simulation

Bike Crank Problem –


Consider a crank mounted on a bicycle as illustrated in the picture below. When a
rider is pedalling the bicycle, she or he is applying a variable force to this bike crank. To
simplify the analysis, we'll neglect the variation of the force with time and focus on the
response of the crank to a static force. This is analogous to taking a video of the bike crank
and analysing a single frame by itself.
In this module, we will work with the following crank model. The geometry will be
provided to you as a download. The crank is made of aluminum 6061-T6 alloy. For this
material, the Young's modulus is 1x107 psi and the Poisson's Ratio is 0.33.

The left three-hole surfaces are fixed and a load of 100 lbf is applied on the right
hole surface in the upward direction. Note that this is an approximation of the actual loads
and constraints on the bike crank.
Using ANSYS Mechanical, we will calculate the following:
• Deformed shape and displacement field
• Stress distribution in the crank
We verify our results by undertaking a systematic process for checking results.

Figure 3.2.2 – Bike Crank


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A Hands-on Introduction to Engineering Simulation

The problem was solved following the problem specifications as show above. The
ANSYS results was obtained and validated using formula. The same problem with few
modifications was given as assignment.

3.2.3 MODULE 3: FINITE ELMENT ANALYSIS (FEA) (BOLTED NOZZLE FLANGE)

In this module, we learnt to:


• Build a nonlinear finite-element model to analyze a bolted assembly
• Model contacts between parts in an assembly
• Model thermal strains
• Verify the finite-element model by refining the mesh and also comparing with hand
calculations

Problem Definition –
The Saturn V rocket that carried people to the moon is the most powerful machine
ever built. The Saturn V's first stage was powered by five F1 engines. In this exercise, we
analyze the bolted flange joint that connected the mid and lower parts of the F1 engine
nozzle. The figure 3.2.3 and 3.2.4 below shows a picture of the F1 engine and the
corresponding model in ANSYS. Note that the ANSYS model includes only the mid and
lower parts of the nozzle and the bolted flange joint connecting them.

Figure 3.2.3 – Saturn V Rocket Booster


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A Hands-on Introduction to Engineering Simulation

Figure – 3.2.4 Ansys Geometry of booster

Figure 3.2.5 – Close-up Bolt Assembly

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A Hands-on Introduction to Engineering Simulation

We'll analyze this bolted joint by building a non-linear finite element model in
ANSYS. Our main objective is to assess the margin of safety of the flange bolts. We'd also
like to determine the gaps that develop between the jointed parts when the assembly is
loaded.
The pressure due to the exhaust gas in the nozzle is calculated using 1D gas
dynamics. It is assumed to vary linearly along the nozzle axis. The pressure at the exit (z=0)
is 12.17 psi and the pressure at the entrance to the mid-nozzle is 47.72 psi.
The regeneration channels are omitted in the model. In exchange, a free body
diagram is used to deduce the equivalent forces on the mid nozzle and lower nozzle (the
upper nozzle is not modeled here). This force pair is modeled as two separate forces, each
of 1000 lbf. The gas temperature is 700 F which causes thermal strain. We assume that bolt
is pre-loaded to 50% of its breaking strength.
The problem was solved following the problem specifications as show above. The
ANSYS results was obtained and validated using formula. While solving this problem we
learnt the use and need for symmetry in ANSYS. The same problem with few modification
was given as assignment.

3.2.4 MODULE 4 : COMPUTATIONAL FLUID DYNAMICS (CFD) (FLUID DYNAMICS)

Fundamental Laws of Fluid Flow


• Conservation of mass
• Conservation of momentum
• Conservation of energy

What is Computational Fluid Dynamics? (CFD)


• Three conservation laws govern fluid flow
• Mathematical formulation of these laws leads to the governing equations:
– Partial differential equations or
– Integral equations
• These equations are nonlinear and coupled
– Can be solved exactly for a small no. of special cases
– Can be solved approximately using numerical methods on a computer (“CFD”)
• Current CFD technology can handle realistic geometries and complex physics

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A Hands-on Introduction to Engineering Simulation

Finite-Volume Method: Introduction


• The numerical technique we’ll use to solve the governing equations is the FVM
• ANSYS Fluent uses it as do many other commercial CFD codes
• Basic idea: Divide flow domain into little chunks and apply conservation laws using
integral form
– Get system of algebraic equations
• Can also use the FEM to solve the governing equations by converting to a system of
algebraic eqations.
• FVM is preferred in CFD
• Advantage: Applies conservation directly rather than indirectly
• So, we’ll use the FVM to convert the governing equations to a set of algebraic equations.

Laminar Pipe Flow


In this module, you'll learn to:

• Develop the numerical solution to a laminar pipe flow problem in ANSYS Fluent
• Verify the numerical results from ANSYS Fluent
• Connect the ANSYS steps to concepts covered in the Big Ideas in CFD section

Consider fluid flowing through a circular pipe of constant radius as illustrated


below. The figure is not to scale. The pipe diameter D = 0.2 m and length L = 3 m. Consider
the inlet velocity to be constant over the cross-section and equal to 1 m/s. The pressure at
the pipe outlet is 1 atm. Take density ρ = 1 kg/ m3 and coefficient of viscosity µ = 2 x 10 -
3 kg/(m*s). These parameters have been chosen to get a desired Reynolds number of 100
and don't correspond to any real fluid.

Figure 3.2.6 - Pipe

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A Hands-on Introduction to Engineering Simulation

We solve this problem numerically using ANSYS Fluent. We'll look at the
following results:
• Velocity vectors
• Velocity magnitude contours
• Pressure contours
• Velocity profile at the outlet
We verify the results by following a systematic process which includes comparing
the results with the analytical solution in the fully-developed region.

The problem was solved following the problem specifications as show above. The
ANSYS Fluent was used to obtain results and validated. The same problem with few
modifications was given as assignment.

3.3 COURSE ASSIGNMENTS

Assignments were provided for each module. It involved both theoretical and ANSYS
based question. The minimum requirement to pass this course is 60%. Figure 3.3.1 shows
the grade summary.

Figure 3.3.1 – Grade Summary

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A Hands-on Introduction to Engineering Simulation

CHAPTER 4

CONCLUSION

4.1 CONCLUSION

A learner who receives an edX Verified Certificate has agreed to follow the rules.
the edX honor code and completed all of the course's mandatory objectives under its
auspices standards, as well as having our photo identification reviewed to confirm their
identity. Learnt how to use ANSYS simulation software to solve real-world engineering
challenges You obtain vital professional skills that businesses are looking for. The
exceptional quality of the issue introductions and the meticulous pacing through hard
mathematics to get the learner to the point where the ANSYS job makes sense is quite
fascinating. All of the goals were clearly stated and understood.

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