Thermal Simulation
Thermal simulation is at the core of what we do at our Singapore office in BroadTech Engineering.
Types of Thermal Simulation We Do
1. Building Thermal Simulation
2. Electronic Battery/ PCB board Thermal Simulation
3. Thermal Simulation using Matlab, Ansys, Fusion360, Revit, Auto desk inventor
Featured Thermal Simulation Case Studies
CFD Analysis of Heat Transfer in a Helical Coiled Heat Exchanger
Due to compact design helical coiled heat exchangers are used in nuclear power plants where space is a major constraint. The objective of this thermal analysis simulation was to investigate the tube side heat transfer and pressure drop characteristics in a helically coiled heat exchanger.
Important geometrical parameters influencing the physics: helix angle, pitch circle diameter (coil diameter) and pipe diameter.
Optimized block mesh (O-grid, hexa) created using ICEM CFD was used for simulation. Mesh independence test was performed to arrive at optimum mesh. In order to capture heat transfer and friction coefficient, Y+ value for the first node near the wall was kept < 5. A straight length (20D) pipe section was provided before helix section to ensure proper flow development in the test section.
The OpenFOAM FVM solver was used for CFD thermal analysis simulation and appropriate Boundary conditions were used for simulation.
Simulation results indicate that use of helical coil leads to enhanced heat transfer, however, the pressure drop also increases when compared to a flow in a straight pipe flow. The heat transfer enhancement is primarily attributed to the secondary flow observed in the coiled pipe leading to better mixing. Heat transfer coefficient is not uniform along the pipe circumference. It was found to be maximum at the outer side of the coil and minimum at the inner side. The effect of helix angle is found to be insignificant on heat transfer. Despite having increased pressure drop, the advantage of compact design and enhanced heat transfer makes helically coiled tube bundle a suitable choice for compact heat exchangers for nuclear power plant applications.
CFD Thermal Analysis of Turbine Case Cooling (TCC) system
Objective: Assessment of Turbine Case Cooling (TCC) system for cooling uniformity and effectivity.
Background: TCC system was designed by a supplier to Rolls-Royce and was found to cause some serious issues in terms of cooling the turbine cases in various engine lines. A full-scale model was considered for analysis where a fluid volume was extracted from a manufacturing detailed CAD model. The model included large pipes and discharged air into a segment with thousands of tiny impingement holes. Therefore the use of porous media approach was considered to be appropriate along with hexa-tetra meshing approach with prism layers in the tetra mesh regions. FLUENT solver was used and turbulent flow was solved by using k-epsilon turbulence model with wall functions. Also to verify the approach, the mesh was generated with the smallest of details and results obtained from detailed analysis were compared with porous media approach. Porous media approach was then considered right.
Results & Conclusion: Results obtained from this analysis were used to modify the design and better cooling uniformity was achieved. These systems are now present in most of the engines and are working to the desired satisfaction.
Conjugate Heat Transfer (CHT) Analysis on a Power Module of an Electronic Device
Done a CHT analysis on the power module of an electronic device in order to investigate if the maximum temperature exceeds the desired limit for the given conditions.
Meshed different components (with different properties) of the power module separately. Performed the steady-state analyses with a constant heat source term for a given inlet flow velocity and temperature.
Found that the maximum temperature exceeds the desired limit and proposed a few ways to reduce it.
Investigation of Conjugate Heat Transfer in a Nuclear Reactor Fueling Machine
The primary objective of this thermodynamic simulation was to determine the temperature distribution in a fueling machine head during online refueling in a nuclear reactor. Proper cooling of fueling machine head is required to ensure the seals from leaking.
This transient thermal analysis was a very complex problem from the geometry (very narrow flow paths) as well as physics point of view. It required considering all three modes of heat transfer. In this problem, it was important to consider the heat radiation loss from the outer boundary since it contributes significantly to the total heat loss to the ambient along with the natural convective loss.
The optimized hexa mesh (using ICEM CFD) after mesh independence tests was used for simulation. The solver used for this simulation was CFX. The simulation without considering radiation loss significantly over-predicted the temperatures in the fueling machine head. On the other hand including radiation loss from the machine head agreed well with the experimental results. When compared to convection heat loss from the walls radiation loss was comparable (even when wall temperatures are low) and neglecting it may lead to significant errors and call for unwanted design changes.
Thermal Simulation of Battery Module
The objective is to investigate the average heat generated by a battery module. The thermal simulation of one cell, and of a battery module was carried out for the thermal simulation. The air cooling system behavior has been evaluated.
Thermal Analysis of Radiator fan for Water Fording
FSI model analysis of radiator fan for water fording. (Ansa, Star-CCM+, Abaqus)
The objective is to find the pressure and deformation on the radiator fan blade and to recommend design modification.
The thermal analysis involved CFD and FEM thermal analysis of the radiator fan. Design enablers like material change, blade angle and thickness increase are analyzed, and design changes recommended accordingly.
Thermal Simulation Analysis of Oven Design
The objective of the simulation is to understand the temperature distribution over the outer surface of the oven and optimize the gap between the door and control panel to maintain the Specified Temperature at Outer Surface. The CFD Regions are created with different material models like a different set of glasses, insulation, steel walls, air gaps/ducts, electronic components (Capacitors, Motors etc) and ran the CFD case with various turbulence models at a given air flow rate. The outcome is the temperature distribution across the outer wall surface and optimized the gap between door and panel to keep the minimum specified temperature at the outer surface of the oven door. Also suggested the design recommendation for various ducts inside for better thermal system.
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BroadTech Engineering is a Leading Engineering Simulation and Numerical Modelling Consultancy in Singapore.
We Help Our Clients Gain Valuable Insights to Optimize and Improve Product Performance, Reliability, and Efficiency.
We Help Our Clients Gain Valuable Insights to Optimize and Improve Product Performance, Reliability, and Efficiency.
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Customers will be provided with fully tailored Thermal simulation reports which outline the Methodology, in-depth analysis, and recommendations. This insight allows our clients to optimize performance and make informed engineering decisions in a scientific, proven manner. If you are still interested in learning more about Thermal simulation and to see what it can do for you, give us a call today at +6581822236 for a no obligation discussion of your needs. if you have any queries, our knowledgeable and friendly consultants will be happy to answer any of your queries and share with you in details the benefits & features of performing a professional thermal simulation analysis. Alternatively, for quote request, simply email us your technical specifications & requirements to info@broadtechengineering.com