CAE: Thermal Analysis Using Digital Validation techniques to Reduce Product development cycle time Jayasimha Chalasani Mahindra Satyam Integrated Engineering Solutions
Tool Snaps Analysis Snaps Brief Introduction of Computer Aided Engineering: CAE Linear /Non Linear Static Analysis Dynamic Analysis Modal Analysis Steady State & Transient Thermal Analysis NVH Analysis Fatigue Analysis Crash Analysis CFD Analysis Nastran FE - Safe Abaqus ANSYS Fluent ICME - CFD 2
Thermal Analysis- CAE & Industry Transportation (Rail,Road,Aero & Marine) - Engines - Exhaust system - Electric Motors - Transmissions - Cargo systems Industrial & Farm Equipments - Exhaust systems - Transmission - Creep & fatigue - Fluid flow Heavy Industries - Combustion - Furnaces - Heat exchangers - Boilers - HVAC Consumer Packaged Goods & Durables - Packaging simulations - Process simulations - Shelf Life Buildings - Wall & Roof - HVAC - Pumps - Ducts, Pipes - Glass Wide Areas for applications of Thermal Analysis using CAE 3
Benefits of Thermal Analysis Using CAE Global Food and Beverage Major Eliminate the need for costly prototypes and destructive testing Saved upto $ 1.5 Mn on testing program Global HVAC Major Save design time and money. Faster Time to market. Time to Market reduced by 30% Heavy Industries Major Eliminate the massive costs associated with modifications or redesign Optimization of Thermal energy by 25% 4
Success Stories
Thermal Analysis- Paper Industry Customer: A global paper manufacturer based in US. Background: In paper drying section the heat exchanger is maxed out and as a result the final product contains high moisture and can t be send Objective: Identify a feasible design option for reducing the oil temperature gradient of the drier to avoid undesirable thermal gradient on the paper. to market. Challenges: Inflow The process for paper manufacturing is not operating at the target efficiency because of the paper rupture during the drying operation. This results in wastage of raw material as well as the processing cost and brings the efficiency down by 10 to 15 %. The major challenge observed is to improve the thermal efficiency of the process by 10 to 15%. Geometry Outflow 6
Thermal Analysis- Paper Industry Methodology: Understand the flow behavior of the base model to determine the cause for undesirable thermal gradient. Propose new design options to reduce the thermal gradient. Evaluate the design options based on fabrication feasibility. Finalize the design for fabrication. Analysis Benefits: Even drying of the paper across the width. No paper rupture observed. 10% improvement in thermal efficiency achieved. $0.75 Mn cost saved for the lines. Best Concept 7
Thermal Analysis- Paper Industry 8
Thermal Analysis: Steam Turbine Casing Customer: A global manufacturer of power generation equipment. Background: Steam turbine design cycle extends over a large period and hence use predictive engineering extensively to reduce time to market. Challenges: CAE analysis has to predict the thermal stresses on various regions of the steam turbine for start-up and shutdown cycles. Transient analysis with high correlation requirements to avoid re-work and reduce design iterations. 9
Thermal Analysis: Steam Turbine Casing Methodology: Non-linear analysis carried out for operating loads on the existing design. Contact study done to predict leakage & rubbing between shell & packing. Design changes suggested to reduce leakage, ovulation and stress. Different trials with calculating the heat transfer coefficient from the physics based correlations at each time point of the transient steam flow. Design changes verified through analysis results. 10
Thermal Analysis: Steam Turbine Casing Benefits: Estimated bolting sequence, leakage, creep, fatigue life estimation, critical frequencies and dynamic stress levels. Design validation done as per the ASME Boilers and Pressure vessels standards (section VIII) and API. Reducing analysis cycle time drastically as the macros developed can be re-used for similar projects. Cost effective as the optimization exercise performed reduces the use of costly bolts with out compromising the performance. 11
Thermal Analysis: Heat exchangers Customer: A global manufacturer of HVAC systems Background: A crack in a heat exchanger can kill everyone in a home in as little as 10 minutes. Environment Protection Agency (EPA) has set a maximum allowable exposure concentration of only 9 PPM or parts per million (0.0009%). Challenges: To simulate the fatigue life of a heat exchanger and estimate the number of cycles at which the design can fail. Material properties data at specific operating conditions of the heat exchangers. 12
Thermal Analysis: Heat Exchangers Methodology: Perform thermo-structural analysis (including material plasticity) on the heat exchanger assembly. The heat exchanger base model has been analyzed to predict the failure points. Temperature (IR image) data was captured experimentally and was given as input to FEA tools and steady state analysis was performed. To reduce the cycle time of the analysis for different temperature profiles, Macro was developed to read the temperature profile in to FEA software. 13
Thermal Analysis: Heat Exchangers Benefits: Established methodology and procedure for predicting the failure points of the heat exchanger, the same procedure can be used for modified design of the heat exchangers. Macro was developed in FEA software to read IR image temperature profile; this feature will be helpful in solving the design iterations in a faster time for any design modifications. Proposal for effective methodology and procedure for simulation of failure points which in-turn eliminate the number of prototype tests to achieve extend life of the heat exchanger. Cost effective and reduces the time to market. 14
Thermal Analysis- Health Care and Hygiene Customer: A global Health Care and Hygiene company based in US. Background: Surgical gloves are cured in the oven of length 50 m at 130 0 C. Due to uneven thermal energy transfer, the curing process is generating wastage. Challenges: The process of surgical glove manufacturing is not operating at the target efficiency because of the uneven curing operation. This results in wastage of surgical gloves while stripping operation to the tune of 8 to 10% because of uneven curing. The major challenge observed is to optimize the process to improve thermal efficiency by 10% Objective: Identify a feasible design option to achieve the uniform heat transfer with time reduction on the former surface by optimizing the former design. Geometry 15
Thermal Analysis- Health Care and Hygiene Methodology: Understand the hot air flow and former movement behavior of the base case to determine the cause for uneven heat transfer. Propose new design options to reduce the uneven heat transfer. Evaluate the design options based on fabrication feasibility. Finalize the design for fabrication. Analysis Benefits: Even heat transfer across the length of the oven. Reduced wastage to 3% $2 Mn cost savings achieved for the lines. Best concept 16
Thermal Analysis- Health Care and Hygiene Before: Temp 391 0 K Time : 25.2 s After: Temp 403 0 K Time : 25.2 s 17
Thank You mahindrasatyam.net Safe Harbor This document contains forward-looking statements within the meaning of section 27A of Securities Act of 1933, as amended, and section 21E of the Securities Exchange Act of 1934, as amended. The forward-looking statements contained herein are subject to certain risks and uncertainties that could cause actual results to differ materially from those reflected in the forward-looking statements. Satyam undertakes no duty to update any forward-looking statements. For a discussion of the risks associated with our business, please see the discussions under the heading Risk Factors in our report on Form 6-K concerning the quarter ended September 30, 2008, furnished to the Securities and Exchange Commission on 07 November, 2008, and the other reports filed with the Securities and Exchange Commission from time to time. These filings are available at http://www.sec.gov 18