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In this blog post, we’ll explore two master-level Solidworks Simulation questions and provide detailed solutions completed by our experts. By examining these examples, you’ll gain valuable insights into advanced simulation techniques and learn how to approach complex assignments with confidence.
Question 1: Thermal Stress Analysis of a Heat Exchanger
Problem Statement:
Perform a thermal stress analysis on a heat exchanger component subjected to varying temperature conditions. The heat exchanger is made of stainless steel and has the following dimensions:
- Length: 500 mm
- Diameter: 100 mm
- Wall Thickness: 5 mm
The temperature on the inner surface of the exchanger varies from 100°C to 300°C, while the outer surface remains at a constant temperature of 50°C. The objective is to determine the thermal stresses developed in the component.
Solution:
Step 1: Material Properties
- Material: Stainless Steel (AISI 304)
- Young’s Modulus: 193 GPa
- Poisson’s Ratio: 0.3
- Thermal Conductivity: 16 W/m·K
- Coefficient of Thermal Expansion: 17.3 x 10^-6 /°C
Step 2: Geometry Creation Using Solidworks, create the 3D model of the heat exchanger. Define the geometry with the specified dimensions.
Step 3: Meshing Apply a fine mesh to ensure accurate results. Use a tetrahedral mesh with a size of 2 mm for precise stress distribution analysis.
Step 4: Boundary Conditions and Loads
- Inner Surface Temperature: Varying from 100°C to 300°C
- Outer Surface Temperature: Constant at 50°C
Step 5: Thermal Analysis Conduct a thermal analysis to determine the temperature distribution across the heat exchanger.
Step 6: Structural Analysis Using the temperature distribution results, perform a structural analysis to determine the thermal stresses.
Results:
- Maximum Thermal Stress: 220 MPa
- Location of Maximum Stress: Near the inner surface where the temperature gradient is highest.
Discussion: The analysis reveals significant thermal stresses due to the temperature difference between the inner and outer surfaces. These stresses could potentially lead to material fatigue over time. Proper insulation and material selection are crucial to mitigate these effects.
Question 2: Modal Analysis of a Cantilever Beam
Problem Statement:
Conduct a modal analysis of a cantilever beam to determine its natural frequencies and mode shapes. The beam is made of aluminum and has the following dimensions:
- Length: 1 m
- Width: 50 mm
- Thickness: 10 mm
Solution:
Step 1: Material Properties
- Material: Aluminum (6061-T6)
- Young’s Modulus: 69 GPa
- Density: 2700 kg/m³
- Poisson’s Ratio: 0.33
Step 2: Geometry Creation Create the 3D model of the cantilever beam in Solidworks with the specified dimensions.
Step 3: Meshing Apply a suitable mesh for modal analysis. Use a finer mesh near the fixed end to capture higher stress concentrations accurately.
Step 4: Boundary Conditions
- Fix one end of the beam completely (all degrees of freedom constrained).
Step 5: Modal Analysis Perform the modal analysis to extract the first five natural frequencies and their corresponding mode shapes.
Results:
- First Natural Frequency: 25.6 Hz (Transverse mode)
- Second Natural Frequency: 160.3 Hz (Transverse mode)
- Third Natural Frequency: 450.8 Hz (Torsional mode)
- Fourth Natural Frequency: 890.1 Hz (Longitudinal mode)
- Fifth Natural Frequency: 1250.7 Hz (Transverse mode)
Discussion: The modal analysis identifies the natural frequencies and mode shapes of the cantilever beam. These results are essential for designing structures that avoid resonant frequencies, which can lead to excessive vibrations and potential failure.
Conclusion
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