ELLIPTICAL AND TORISPHERICAL PRESSURE VESSEL

HEADS DESIGN AND ANALYSIS BY USING CAD/CAE

TOOLS

Abstract

A pressure vessel is a container designed to hold gases or liquids at

a pressure substantially different from the ambient pressure. The pressure differential is
dangerous, and fatal accidents have occurred in the history of pressure vessel development and
operation. Consequently, pressure vessel design, manufacture, and operation are regulated by
engineering authorities backed by legislation. For these reasons, the definition of a pressure
vessel varies from country to country; A head is one of the end caps on a cylindrically
shaped pressure vessel. The shape of the heads used can vary. The most common head shapes
are:

(i)Ellipsoidal head
(ii)Torispherical head
In this project we are considering 2 different pressure vessel heads and those are
elliptical pressure vessel head and TORISPHERICAL pressure vessel head and analyzing with
different materials properties with real-time boundary conditions. In this project elliptical with
cu-alloy material considering as existing model and existing material, to improve its strength
here we also had taken another 3 materials with changing vessel head (TORISPHERICAL
pressure vessel head).

Tools were used:

CAD TOOL: CREO-2

CAE TOOL: ANSYS WORKBENCH
 1. INTRODUCTION

A pressure vessel is a container designed to hold gases or liquids at a pressure substantially

different from the ambient pressure. The pressure differential is dangerous, and fatal accidents
have occurred in the history of pressure vessel development and operation. Consequently,
pressure vessel design, manufacture, and operation are regulated by engineering authorities
backed by legislation. For these reasons, the definition of a pressure vessel varies from country to
country, but involves parameters such as maximum safe operating pressure and temperature, and
are engineered with a safety factor, corrosion allowance, minimum design temperature (for brittle
fracture), and involve non-destructive testing, such as testing, radiography, and pressure tests,
usually involving water, also known as a hydro test, but could be pneumatically tested involving
air or another gas. The preferred test is hydrostatic testing because it's a much safer method of
testing as it releases much less energy if fracture were to occur (water does not rapidly increase
its volume while rapid depressurization occurs, unlike gases like air, i.e. gasses fail explosively).
In the United States, as with many other countries, it is the law that vessels over a certain size and
pressure (15 PSIg) be built to Code, in the United States that Code is the ASME Boiler and
Pressure Vessel Code (BPVC), these vessels also require an Authorized Inspector to sign off on
every new vessel constructed and each vessel has a nameplate with pertinent information about
the vessel such as maximum allowable working pressure, maximum temperature, minimum
design metal temperature, what company manufactured it, the date, its registration number
(through the National Board), and ASME's official stamp for pressure vessels (U-stamp), making
the vessel traceable and officially an ASME Code vessel.

Pressure vessel features

Shape of a pressure vessel

Pressure vessels can theoretically be almost any shape, but shapes made of sections of spheres,
cylinders, and cones are usually employed. A common design is a cylinder with end caps
called heads. Head shapes are frequently either hemispherical or dished (torispherical). More
complicated shapes have historically been much harder to analyze for safe operation and are
usually far more difficult to construct.

Spherical gas container:

Cylindrical pressure vessel.

Theoretically, a spherical pressure vessel has approximately twice the strength of a cylindrical
pressure vessel with the same wall thickness, and is the ideal shape to hold internal pressure.
However, a spherical shape is difficult to manufacture, and therefore more expensive, so most
pressure vessels are cylindrical with 2:1 semi-elliptical heads or end caps on each end. Smaller
pressure vessels are assembled from a pipe and two covers. For cylindrical vessels with a diameter up
to 600 mm (NPS of 24 in), it is possible to use seamless pipe for the shell, thus avoiding many
inspection and testing issues, mainly the non-destructive examination of radiography for the long
seam if required. A disadvantage of these vessels is that greater diameters are more expensive, so that
for example the most economic shape of a 1,000 litres (35 cu ft), 250 bars (3,600 psi) pressure vessel
might be a diameter of 91.44 centimetres (36 in) and a length of 1.7018 metres (67 in) including the
2:1 semi-elliptical domed end caps.
Head (vessel):

A head is one of the end caps on a cylindrically shaped pressure vessel. Head design in
pressure vessels are a challenging task. For the pressure vessels, different types of heads or
ends can be provided

Shapes

The shape of the heads used can vary. The most common head shapes are

Hemispherical head

A sphere is the ideal shape for a head, because the pressure in the vessel is divided equally across
the surface of the head. The radius (r) of the head equals the radius of the cylindrical part of the
vessel

Ellipsoidal head

This is also called an elliptical head. The shape of this head is more economical, because the
height of the head is just a fraction of the diameter. Its radius varies between the major and minor
axis; usually the ratio is 2:1.

Torispherical head

These heads have a dish with a fixed radius (r1), the size of which depends on the type of
torispherical head The transition between the cylinder and the dish is called the knuckle. The
knuckle has a toroidal shape.
The most common types of torispherical heads are

Flat head

This is a head consisting of a toroidal knuckle connecting to a flat plate. This type of head is
typically used for the bottom of cookware.
 1.1.LITERATURE REVIEW

One of the major problems that is faced during the operation of thin-walled structures is buckling.
In buckling structural members collapse under compressive loads greater than the material can
withstand. Torispherical pressure vessel heads are sensitive to geometric or load imperfections
due to unstable post-buckling behavior. Finite element analysis is widely used in the design of
these structures [1,2]. Extensive studies are presented on the buckling of pressure vessels [3-8].
Athiannan and Palaninathan presented experimental studies on buckling of thin-walled circular
cylindrical shells under transverse shear. The buckling loads are also obtained from finite element
models, empirical formulae and codes and are compared [9]. Godoy’s study deals with the
modeling of shape deviations in thin-walled plates and shells using finite elements together with
perturbation techniques [10]. Khan et al. presented an experimental technique for the buckling
test of shells under external pressure to determine buckling load [11]. Miller worked on buckling
criteria for torispherical heads under internal pressure which are especially outside the limits of
ASME codes [12]. Layered structures are widely used in as diverse applications as in aircrafts,
thin film deposition in semiconductor devices, heat exchangers, etc. Such structures are subjected
to a variety of loading types with some of them being capable of causing buckling. Rutgerson and
Botega’s study provides details about a wider study in to the elastic buckling behavior of circular
panels for combination of temperature, external pressure and edge loading [13]. Guz and Dyshel
studied loss of local stability in a cracked bimetal plate [14]. Muscat et al. proposed a criterion
for evaluating the critical limit values and determining the plastic loads inpressure vessel design
[15]. Blachut’s study presents results of a numerical and experimental investigation into static
stability of externally pressurized layered hemispherical and torispherical domes.
Buckling/collapse tests are also conducted on domes from various materials [16]. Mackenzie et
al. made an extensive review on the descriptions of the EN13445 and ASME Boiler and pressure
vessel code contents [17]. The ASME Twice Elastic Slope (TES), criterion uses an empirical
procedure for calculating collapse loads in experimental stress analysis of pressure vessels.
Mackenzie et al. considered small and large deformation effects and the geometry and load
perturbations. Their study contains the formation of the gross plastic deformation mechanism in
the models in relation to the elastic–plastic buckling response of the vessels. In their study both
ASME TES and plastic work criteria (PWC) are considered. The PWC criterion requires a plot of
load against normalized load-plastic work curvature [17].
 1.2. TORISPHERICAL HEAD

Thin-walled torispherical pressure vessel heads have a wide usage area in industry. One of the
major problems that is faced during the operation of thin-walled structures is buckling. In
buckling structural members collapse under compressive loads greater than the material can
withstand. Torispherical pressure vessel heads are sensitive to geometric or load imperfections
due to unstable post-buckling behaviour. Finite element analysis is widely used in the design of
these structures.

DETERMINATION OF THICKNESS OF SHELL ENDS:

Here two different types of heads/ends are taken into account.

a) Type1- (Torispherical, Hemispherical and Elliptical Head):
In “BS 1113” the formulae used for determination of thickness of torispherical head are
applicable to semi elliptical and hemispherical heads, hence analytical solution of only
torisperical is shown.

Using the notations in the figure,

torispherical head
i) Ri shall not be greater than Do
ii) The internal corner radius “ri” shall neither be less than 10% of Do nor less than 3 times
thickness of shell end
iii) The external height H shall not be less than 0.18 Do
Thickness of shell end = tse =P Do K/2 f
Let H = 0.18 x Do
But as the minimum thickness tse shall in no circumstances be less than 9.5 mm,
 2. INTRODUCTION:

CREO
2.1. CAD
Computer aided design (cad) is defined as any activity that involves the

effective use of the computer to create, modify, analyze, or document an engineering design.

CAD is most commonly associated with the use of an interactive computer graphics system,

referred to as cad system. The term CAD/CAM system is also used if it supports

manufacturing as well as design applications

2.2. Introduction to CREO

CREO is a suite of programs that are used in the design, analysis, and manufacturing of a

virtually unlimited range of product.

CREO is a parametric, feature-based solid modeling system, “Feature based”

means that you can create part and assembly by defining feature like pad, rib, slots, holes, rounds,

and so on, instead of specifying low-level geometry like lines, arcs, and circle& features are

specifying by setting values and attributes of element such as reference planes or surfaces

direction of creation, pattern parameters, shape, dimensions and others.

“Parametric” means that the physical shape of the part or assembly is driven

by the values assigned to the attributes (primarily dimensions) of its features. Parametric may

define or modify a feature’s dimensions or other attributes at any time.

 For example, if your design intent is such that a hole is centered on a block, you

can relate the dimensional location of the hole to the block dimensions using a numerical

formula; if the block dimensions change, the centered hole position will be recomputed

automatically.

“Solid Modeling” means that the computer model to create it able to contain all the

information that a real solid object would have. The most useful thing about the solid

modeling is that it is impossible to create a computer model that is ambiguous or physically

non-realizable.

There are six core CREO concepts. Those are:

 Solid Modeling

 Feature Based

 Parametric

 Parent / Child Relationships

 Associative

 Model Centric
2.3 Capabilities and Benefits:

1. Complete 3D modeling capabilities enable you to exceed quality arid time to arid time

to market goals.

2. Maximum production efficiency through automated generation of associative C tooling

design, assembly instructions, and machine code.

3. Ability to simulate and analysis virtual prototype to improve production performance

and optimized product design.

 4. Ability to share digital product data seamlessly among all appropriate team members

5. Compatibility with myriad CAD tools-including associative data exchange and

industry standard data formats.

2.4 Features of CREO

CREO is a one-stop for any manufacturing industry. It offers effective feature,

incorporated for a wide variety of purpose. Some of the important features are as follows:

 Simple and powerful tool

 Parametric design

 Feature-based approach

 Parent child relationship

 Associative and model centric

2.4.1. Simple and Powerful Tool

CREO tools are used friendly. Although the execution of any operation using the tool can

create a highly complex model

2.4.2. Parametric Design

CREO designs are parametric. The term “parametric” means that the design operations

that are captured can be stored as they take place. They can be used effectively in the future

for modifying and editing the design. These types of modeling help in faster and easier

modifications of design.
2.4.3. Feature-Based Approach

Features are the basic building blocks required to create an object. CREO wildfire models

are based on the series of feature. Each feature builds upon the previous feature, to create the

model (only one single feature can be modified at a time). Each feature may appear simple,

individually, but collectively forms a complex part and assemblies.

The idea behind feature based modelling is that the designer construct on object, composed

of individual feature that describe the manner in which the geometry supports the object, if its

dimensions change. The first feature is called the base feature.

2.4.4. Parent Child Relationship

The parent child relationship is a powerful way to capture your design intent in a model. This

relationship naturally occurs among features, during the modeling process. When you create a

new feature, the existing feature that are referenced, become parent to the feature.

2.4.5. Associative and Model Centric

CREO drawings are model centric. This means that CREO models that are represented in

assembly or drawings are associative. If changes are made in one module, these will

automatically get updated in the referenced module.

2.5. CREO Basic Design Modes

When a design from conception to completion in CREO, the design information goes through three

basic design steps.

1. Creating the component parts of the design

2. Joining the parts in an assembly that records the relative position of the parts.
 3. Creating mechanical drawing based on the information in the parts and the assembly.

2.6 Assembly in CREO:

Bottom-Up Design (Modeling):

The components (parts) are created first and then added to the assembly file. This technique

is particularly useful when parts already exist from previous designs and are being re-used.

Top-Down Design (Modeling):

The assembly file is created first and then the components are created in the

assembly file. The parts are build relative to other components. Useful in new designs

In practice, the combination of Top-Down and Bottom-Up approaches is used. As you often

use existing parts and create new parts in order to meet your design needs.

Degrees of Freedom:

An object in space has six degrees of freedom.

• Translation – movement along X, Y, and Z axis (three degrees of freedom)

• Rotation – rotate about X, Y, and Z axis (three degrees of freedom)

Assembly Constraints:

In order to completely define the position of one part relative to another, we must constrain all

of the degrees of freedom COINCIDENT, OFFSET

OFFSET

Two surfaces are made parallel with a specified offset distance..

COINCIDENT

Two selected surfaces become co-planar and face in the same direction. Can also be applied to

revolved surfaces. This constrains 3 degrees of freedom (two rotations and one translation). When

Align is used on revolved surfaces, they become coaxial (axes through the centers align).

CREO Modules:-

 Sketcher (2D)

 Part (3D)

 Assembly

 Drawing and Drafting

 Sheet Metal

 Surface modeling

3D MODEL IS DEVELOPED USING CREO:-

Open pro-e/creo
New enter namepressure vessel heads modelok
 Then we will get a new window

Create model with dimensions

Elliptical pressure vessel head dimensions

The above sketch should follow 3 conditions those are the sketcher should be closed and there
should be no open end there should be no over lapping. By following these conditions we have to
create our model. After completion of sketch click ok and we will get below model.
The above sketch is our final sketch

Now select revolveselect sketchok

Revolving elliptical pressure vessel head

Elliptical pressure vessel head

Repeat the same process for other pressure vessel head also

Create model with dimensions

Torispher pressure vessel head dimensions

The above sketch is our final sketch

Now select revolveselect sketchok

 Revolving torispher pressure vessel head

Torispher Pressure Vessel Head

Then save all these models as IGES format to import into Ansys
 INTRODUCTION TO FEA

Finite Element Analysis (FEA) was first developed in 1943 by R. Courant, who utilized the Ritz
method of numerical analysis and minimization of variational calculus to obtain approximate
solutions to vibration systems. Shortly thereafter, a paper published in 1956 by M. J. Turner, R.
W. Clough, H. C. Martin, and L. J. Topp established a broader definition of numerical analysis.
The paper centered on the "stiffness and deflection of complex structures".

FEA consists of a computer model of a material or design that is stressed and analyzed for
specific results. It is used in new product design, and existing product refinement. A company is
able to verify a proposed design will be able to perform to the client's specifications prior to
manufacturing or construction. Modifying an existing product or structure is utilized to qualify
the product or structure for a new service condition. In case of structural failure, FEA may be
used to help determine the design modifications to meet the new condition.

There are generally two types of analysis that are used in industry: 2-D modeling, and 3-D
modeling. While 2-D modeling conserves simplicity and allows the analysis to be run on a
relatively normal computer, it tends to yield less accurate results. 3-D modeling, however,
produces more accurate results while sacrificing the ability to run on all but the fastest computers
effectively. Within each of these modeling schemes, the programmer can insert numerous
algorithms (functions) which may make the system behave linearly or non-linearly. Linear
systems are far less complex and generally do not take into account plastic deformation. Non-
linear systems do account for plastic deformation, and many also are capable of testing a material
all the way to fracture.

FEA uses a complex system of points called nodes which make a grid called a mesh. This mesh
is programmed to contain the material and structural properties which define how the structure
will react to certain loading conditions. Nodes are assigned at a certain density throughout the
material depending on the anticipated stress levels of a particular area. Regions which will
receive large amounts of stress usually have a higher node density than those which experience
little or no stress. Points of interest may consist of: fracture point of previously tested material,
fillets, corners, complex detail, and high stress areas. The mesh acts like a spider web in that from
each node, there extends a mesh element to each of the adjacent nodes. This web of vectors is
what carries the material properties to the object, creating many elements.

A wide range of objective functions (variables within the system) are available for
minimization or maximization:

 Mass, volume, temperature

 Strain energy, stress strain

 Force, displacement, velocity, acceleration

 Synthetic (User defined)

There are multiple loading conditions which may be applied to a system. Some examples are
shown:

 Point, pressure, thermal, gravity, and centrifugal static loads

 Thermal loads from solution of heat transfer analysis

 Enforced displacements

 Heat flux and convection

 Point, pressure and gravity dynamic loads

Each FEA program may come with an element library, or one is constructed over time. Some
sample elements are:

 Rod elements

 Beam elements

 Plate/Shell/Composite elements

 Shear panel

 Solid elements
  Spring elements

 Mass elements

 Rigid elements

 Viscous damping elements

Many FEA programs also are equipped with the capability to use multiple materials within the
structure such as:

 Isotropic, identical throughout

 Orthotropic, identical at 90 degrees

 General anisotropic, different throughout

3.1 TYPES OF ENGINEERING ANALYSIS

Structural analysis consists of linear and non-linear models. Linear models use simple
parameters and assume that the material is not plastically deformed. Non-linear models consist
of stressing the material past its elastic capabilities. The stresses in the material then vary with
the amount of deformation as in.

Vibrational analysis is used to test a material against random vibrations, shock, and impact.
Each of these incidences may act on the natural vibrational frequency of the material which, in
turn, may cause resonance and subsequent failure.

Fatigue analysis helps designers to predict the life of a material or structure by showing the
effects of cyclic loading on the specimen. Such analysis can show the areas where crack
propagation is most likely to occur. Failure due to fatigue may also show the damage tolerance
of the material.
Heat Transfer analysis models the conductivity or thermal fluid dynamics of the material or
structure. This may consist of a steady-state or transient transfer. Steady-state transfer refers to
constant thermo properties in the material that yield linear heat diffusion.

3. 2Results of Finite Element Analysis

FEA has become a solution to the task of predicting failure due to unknown stresses by
showing problem areas in a material and allowing designers to see all of the theoretical
stresses within. This method of product design and testing is far superior to the manufacturing
costs which would accrue if each sample was actually built and tested.
In practice, a finite element analysis usually consists of three principal steps:

1. Preprocessing: The user constructs a model of the part to be analyzed in which the
geometry is divided into a number of discrete sub regions, or elements," connected at
discrete points called nodes." Certain of these nodes will have fixed displacements, and
others will have prescribed loads. These models can be extremely time consuming to
prepare, and commercial codes vie with one another to have the most user-friendly
graphical “preprocessor" to assist in this rather tedious chore. Some of these
preprocessors can overlay a mesh on a preexisting CAD file, so that finite element
analysis can be done conveniently as part of the computerized drafting-and-design
process.

2. Analysis: The dataset prepared by the preprocessor is used as input to the finite
element

code itself, which constructs and solves a system of linear or nonlinear algebraic equations

Kijuj = fi

where u and f are the displacements and externally applied forces at the nodal points. The
formation of the K matrix is dependent on the type of problem being attacked, and this module
will outline the approach for truss and linear elastic stress analyses. Commercial codes may
have very large element libraries, with elements appropriate to a wide range of problem types.
One of FEA's principal advantages is that many problem types can be addressed with the same
code, merely by specifying the appropriate element types from the library.

3. Postprocessing: In the earlier days of finite element analysis, the user would pore
through reams of numbers generated by the code, listing displacements and stresses at
discrete positions within the model. It is easy to miss important trends and hot spots
this way, and modern codes use graphical displays to assist in visualizing the results. A
typical postprocessor display overlays colored contours representing stress levels on
the model, showing a full field picture similar to that of photo elastic or moiré
experimental results
 4. INTRODUCTION TO ANSYS

4.1 INTRODUCTION

ANSYS is general-purpose finite element analysis (FEA) software package.  Finite Element
Analysis is a numerical method of deconstructing a complex system into very small pieces (of
user-designated size) called elements. The software implements equations that govern the
behaviour of these elements and solves them all; creating a comprehensive explanation of how
the system acts as a whole. These results then can be presented in tabulated, or graphical
forms.  This type of analysis is typically used for the design and optimization of a system far
too complex to analyze by hand.  Systems that may fit into this category are too complex due
to their geometry, scale, or governing equations.

ANSYS is the standard FEA teaching tool within the Mechanical Engineering Department at
many colleges. ANSYS is also used in Civil and Electrical Engineering, as well as the Physics
and Chemistry departments. 

ANSYS provides a cost-effective way to explore the performance of products or processes in a

virtual environment. This type of product development is termed virtual prototyping.

With virtual prototyping techniques, users can iterate various scenarios to optimize the product
long before the manufacturing is started. This enables a reduction in the level of risk, and in
the cost of ineffective designs. The multifaceted nature of ANSYS also provides a means to
ensure that users are able to see the effect of a design on the whole behavior of the product, be
it electromagnetic, thermal, mechanical etc

4.1.1 GENERIC STEPS TO SOLVING ANY PROBLEM IN ANSYS: 

Like solving any problem analytically, you need to define (1) your solution domain, (2) the
physical model, (3) boundary conditions and (4) the physical properties. You then solve the
problem and present the results. In numerical methods, the main difference is an extra step
called mesh generation. This is the step that divides the complex model into small elements
that become solvable in an otherwise too complex situation. Below describes the processes in
terminology slightly more attune to the software.
4.1.1.1 BUILD GEOMETRY

Construct a two or three dimensional representation of the object to be modelled and tested
using the work plane coordinates system within ANSYS.

4.1.1.2 DEFINE MATERIAL PROPERTIES

Now that the part exists, define a library of the necessary materials that compose the object (or
project) being modelled.  This includes thermal and mechanical properties.

4.1.1.3 GENERATE MESH

At this point ANSYS understands the makeup of the part.  Now define how the modeled
system should be broken down into finite pieces. 

4.1.1.4 APPLY LOADS

Once the system is fully designed, the last task is to burden the system with constraints, such
as physical loadings or boundary conditions.

4.1.1.5 OBTAIN SOLUTION

This is actually a step, because ANSYS needs to understand within what state (steady state,
transient… etc.) the problem must be solved.

4.1.1.6 PRESENT THE RESULTS

After the solution has been obtained, there are many ways to present ANSYS’ results, choose
from many options such as tables, graphs, and contour plots. 

4.2 SPECIFIC CAPABILITIES OF ANSYS:

4.2.1 STRUCTURAL 

Structural analysis is probably the most common application of the finite element method as it
implies bridges and buildings, naval, aeronautical, and mechanical structures such as ship
hulls, aircraft bodies, and machine housings, as well as mechanical components such as
pistons, machine parts, and tools. 

·         Static Analysis - Used to determine displacements, stresses, etc. under static loading
conditions. ANSYS can compute both linear and nonlinear static analyses. Nonlinearities can
include plasticity, stress stiffening, large deflection, large strain, hyper elasticity, contact
surfaces, and creep. 
Modal Analysis

A modal analysis is typically used to determine the vibration characteristics (natural

frequencies and mode shapes) of a structure or a machine component while it is being
designed. It can also serve as a starting point for another, more detailed, dynamic analysis,
such as a harmonic response or full transient dynamic analysis.

Modal analyses, while being one of the most basic dynamic analysis types available in
ANSYS, can also be more computationally time consuming than a typical static analysis.  A
reduced solver, utilizing automatically or manually selected master degrees of freedom is used
to drastically reduce the problem size and solution time.

Harmonic Analysis - Used extensively by companies who produce rotating machinery,

ANSYS Harmonic analysis is used to predict the sustained dynamic behavior of structures to
consistent cyclic loading.  Examples of rotating machines which produced or are subjected to
harmonic loading are:

 Turbines

o Gas Turbines for Aircraft and Power Generation

o Steam Turbines

o Wind Turbine

o Water Turbines

o Turbo pumps

 Internal Combustion engines

 Electric motors and generators

 Gas and fluid pumps

 Disc drives

A harmonic analysis can be used to verify whether or not a machine design will successfully
overcome resonance, fatigue, and other harmful effects of forced vibrations.
·         Transient Dynamic Analysis - Used to determine the response of a structure to
arbitrarily time-varying loads. All nonlinearities mentioned under Static Analysis above are
allowed. 

·         Buckling Analysis - Used to calculate the buckling loads and determine the buckling
mode shape. Both linear (eigenvalue) buckling and nonlinear buckling analyses are possible.  

In addition to the above analysis types, several special-purpose features are available such as
Fracture mechanics, Composite material analysis, Fatigue, and both p-Method and Beam
analyses.  

4.2.2 THERMAL 

ANSYS is capable of both steady state and transient analysis of any solid with thermal
boundary conditions. 

Steady-state thermal analyses calculate the effects of steady thermal loads on a system or
component. Users often perform a steady-state analysis before doing a transient thermal
analysis, to help establish initial conditions. A steady-state analysis also can be the last step of
a transient thermal analysis; performed after all transient effects have diminished. ANSYS can
be used to determine temperatures, thermal gradients, heat flow rates, and heat fluxes in an
object that are caused by thermal loads that do not vary over time. Such loads include the
following: 

·         Convection

·         Radiation

·         Heat flow rates

·         Heat fluxes (heat flow per unit area)

·         Heat generation rates (heat flow per unit volume)

·         Constant temperature boundaries

A steady-state thermal analysis may be either linear, with constant material properties; or
nonlinear, with material properties that depend on temperature. The thermal properties of most
material vary with temperature. This temperature dependency being appreciable, the analysis
becomes nonlinear. Radiation boundary conditions also make the analysis nonlinear. Transient
calculations are time dependent and ANSYS can both solve distributions as well as create
video for time incremental displays of models.
4.2.3 FLUID FLOW

The ANSYS/FLOTRAN CFD (Computational Fluid Dynamics) offers comprehensive tools

for analyzing two-dimensional and three-dimensional fluid flow fields.  ANSYS is capable of
modeling a vast range of analysis types such as: airfoils for pressure analysis of airplane wings
(lift and drag), flow in supersonic nozzles, and complex, three-dimensional flow patterns in a
pipe bend.  In addition, ANSYS/FLOTRAN could be used to perform tasks including:  

·         Calculating the gas pressure and temperature distributions in an engine exhaust
manifold

·         Studying the thermal stratification and breakup in piping systems

·         Using flow mixing studies to evaluate potential for thermal shock

·         Doing natural convection analyses to evaluate the thermal performance of chips in
electronic enclosures

·         Conducting heat exchanger studies involving different fluids separated by solid regions 

 4.2.4 ACOUSTICS / VIBRATION

ANSYS is capable of modelling and analyzing vibrating systems in order to that vibrate in
order to analyze  

Acoustics is the study of the generation, propagation, absorption, and reflection of pressure
waves in a fluid medium. Applications for acoustics include the following:  

·         Sonar - the acoustic counterpart of radar

·         Design of concert halls, where an even distribution of sound pressure is desired

·         Noise minimization in machine shops

·         Noise cancellation in automobiles

·         Underwater acoustics

·         Design of speakers, speaker housings, acoustic filters, mufflers, and many other similar
devices.

·         Geophysical exploration

Within ANSYS, an acoustic analysis usually involves modelling a fluid medium and the
surrounding structure. Characteristics in question include pressure distribution in the fluid at
different frequencies, pressure gradient, and particle velocity, the sound pressure level, as
well as, scattering, diffraction, transmission, radiation, attenuation, and dispersion of
acoustic waves. A coupled acoustic analysis takes the fluid-structure interaction into account.
An uncoupled acoustic analysis models only the fluid and ignores any fluid-structure
interaction.

The ANSYS program assumes that the fluid is compressible, but allows only relatively small
pressure changes with respect to the mean pressure. Also, the fluid is assumed to be non-
flowing and inviscid (that is, viscosity causes no dissipative effects). Uniform mean density
and mean pressure are assumed, with the pressure solution being the deviation from the mean
pressure, not the absolute pressure.

4.2.5 COUPLED FIELDS

 A coupled-field analysis is an analysis that takes into account the interaction (coupling)
between two or more disciplines (fields) of engineering. A piezoelectric analysis, for example,
handles the interaction between the structural and electric fields: it solves for the voltage
distribution due to applied displacements, or vice versa. Other examples of coupled-field
analysis are thermal-stress analysis, thermal-electric analysis, and fluid-structure analysis.

Some of the applications in which coupled-field analysis may be required are pressure vessels
(thermal-stress analysis), fluid flow constrictions (fluid-structure analysis), induction heating
(magnetic-thermal analysis), ultrasonic transducers (piezoelectric analysis), magnetic forming
(magneto-structural analysis), and micro-electro mechanical systems (MEMS).
 5. ANSYS PROCESS

IMPORTING THE COMPONEENT FROM CAD (CREO) TOOL TO CAE TOOL (ANSYS):

STRUCTURAL ANALYSIS:-
1. Click on Ansys workbench

Static structural

3.engineering dataright click enter values

FOR

Al-5154

Ex: - 69*10^9 Pa

Poison ratio: 0.33

Density: 2660 Kg/m^3

Yield strength: 320 Mpa

Cu alloy

Ex: - 110*10^9 Pa

Poison ratio: 0.34

Density: 8300 Kg/m^3

Yield strength: 280 Mpa

NITINOL

Ex: - 80*10^9 Pa

Poison ratio: 0.33

Density: 6450 Kg/m^3

Yield strength: 500 Mpa

Titanium

Ex: - 96*10^9 Pa

Poison ratio: 0.36

Density: 4620 Kg/m^3

Yield strength: 930 Mpa

4. Geometry right click import geometry import iges format model

Model imported from pro-e tool in IGES format.

Imported elliptical pressure vessel head Model View In Ansys.

After importing model just click on geometry option then we will get selection of material.
From engineering data here we already applied steel and AL-5154, CU-ALLOY, NITINOL,
TITANIUM material properties

After completion of material selection here we have to create meshing for each object
meshing means it is converting single part into no of parts. And this mesh will transfer applied
loads for overall object. After completion meshing only we can solve our object. Without
mesh we cannot solve our problem. And here we are using tetra meshing and the model shown
in below.

Tet Volume Mesh.

 Elliptical pressure vessel head Boundary conditions

After completion of all these here we have to apply boundary conditions on the object

Select geometry assigns material properties

Click on static structural  supportselect edgesok

 loadspressure 1*10^6 pa apply

. Solutiondeformationsolve

Repeat same process for von-misess stress, factor of safety then solve
 Results:
Material: al-5154

Deformation:

The above figure shows the deformation results of elliptical pressure vessel head for AL-5154

material and here we have maximum deformation is 11.06mm and minimum is 0mm.

Stress

The above figure shows the stress results of elliptical pressure vessel head for AL-5154 material

and here we have maximum stress is 141.27Mpa and minimum is 10.117Mpa.

Safety factor

The above figure shows that safety factor values of elliptical pressure vessel head and here we

have 2.2652 safety factor values. And it is greater than 1.so our model was safe.

Strain

The above figure shows the strain results of elliptical pressure vessel head for AL-5154 material

and here we have maximum strain is 0.0020474 and minimum is 0.0003229.

Material: cu alloy

Deformation:

Stress
Safety factor

Strain
Material : NITINOL

Deformation:

Stress
Safety factor

Strain
Material: TITANIUM

Deformation:

Stress
Safety factor

Strain
Tables

Al-5154 Cu-alloy NITINOL TITANIUM

Deformation(mm) 11.06 6.92 9.5392 7.90

Safety factor 2.2652 2.0043 3.5393 6.8308

Strain 0.0020474 0.00127 0.0017659 0.0014182

Stress(Mpa) 141.27 139.7 141.27 136.15

From the above results we can say that cu-alloy (existing material) having 139.7Mpa stress

only and when we use material properties like AL-5154 & NITINOL we got 141.27Mpa stress

and for titanium 136.15Mpa. from all these TITANIUM have very less stress and high

strength and then NITINOL have better results

Graphs

Deformation
 Deformation(mm)
12
10
8
Deformation(mm)
6
4
2
0
Al-5154 Cu-alloy NITINOL TITANIUM

The graph indicates that Al-5154 material has very high deformation values and cu-alloy have

less deformation

Safety Factor

Safety factor
8
7
6
5 Safety factor
4
3
2
1
0
Al-5154 Cu-alloy NITINOL TITANIUM

The graph indicates that cu-alloy has less strength and titanium has well strength.

Strain
 Strain
0

0 Strain

0
Al-5154 Cu-alloy NITINOL TITANIUM

The graph indicates that Al-5154 material has very high strain values and cu-alloy has less

strain.

Stress

Stress(Mpa)
142
140
138 Stress(Mpa)
136
134
132
Al-5154 Cu-alloy NITINOL TITANIUM

The graph indicates that Al-5154 & NITINOL materials have very high stress values and

Titanium has less stress. To reduce this stress amount here are analyzing one more model

called TORISPHERICAL pressure vessel head with same boundary conditions and same

materials.

ANALYSIS PROCESS FOR TORISPHERICAL MODEL

 4. Geometry right click import geometry import iges format model

Model imported from pro-e tool in IGES format.

Imported Model View In Ansys.

Meshing: - Volume Mesh – Tetmesh.

Tet Volume Mesh.

 Boundary conditions

Select geometry assign material properties

Click on static structural  supportselect edgesok

 loadspressure 1*10^6 pa apply

. Solutiondeformationsolve

Repeat same process for von-misess stress, factor of safety then solve

Results:
Material: al-5154
 Deformation:

The above results shows deformation results of torispehre pressure vessel head with AL-5154

material. And here we have maximum deformation is 4.8249mm and minimum is 0mm

Stress

Safety factor
Strain

Material: cu alloy
Deformation:

Stress

Safety factor
Strain

Material: NITINOL

Deformation:
Stress

Safety factor
Strain

Material: TITANIUM
Deformation:

Stress

Safety factor
Strain

Tables:
 Al-5154 Cu-alloy NITINOL TITANIUM

Deformation(mm 4.8249 3.0237 4.1614 3.4572

Safety factor 3.1029 2.7234 4.8483 9.1034

Strain 0.0015365 0.000960 0.0013253 0.0010931

Stress(Mpa) 103.55 102.81 103.13 102.16

The graph indicates that cu-alloy and titanium has almost same amount of stress values 102.81
& 102.16 Mpa respectively. But other materials also have nearby same values there is slight
different only, when compare with elliptical pressure vessel head TORISPHERICAL pressure
vessel head has very less stress.

Graphs
Deformation

Deformation(mm)
6
5
4 Deformation(mm)
3
2
1
0
Al-5154 Cu-alloy NITINOL TITANIUM

The graph indicates that Al-5154 material has very high deformation values and cu-alloy have

less deformation.

Safety factor
 Safety factor
10
9
8
7
6 Safety factor
5
4
3
2
1
0
Al-5154 Cu-alloy NITINOL TITANIUM

The graph indicates that cu-alloy has less strength and titanium has well strength.

Strain

Strain
0
0
0
0
0 Strain

0
0
0
0
0
Al-5154 Cu-alloy NITINOL TITANIUM

The graph indicates that Al-5154 material has very high strain values and cu-alloy has less

strain.

Stress
 Stress(Mpa)
104

103.5

103
Stress(Mpa)
102.5

102

101.5

101
Al-5154 Cu-alloy NITINOL TITANIUM

The graph indicates that Al-5154 & NITINOL materials have very high stress values and
Titanium has less stress.

AND NOW COMPARING BOTH MODELS

Deformation(mm)
18
16 4.82
14 4.16
12 torospherical
11.06 3.46
10 3.02 9.54 eliptiical
8 7.9
6.92
6
4
2
0
Al-5154 Cu-alloy NITINOL TITANIUM
 safety factor
10
9
8
7
eliptiical
6
torospherical
Axis Title 5
4
3
2
1
0
Al-5154 Cu-alloy NITINOL TITANIUM

strain
0

eliptiical
0
torospherical
Axis Title
0

0
Al-5154 Cu-alloy NITINOL TITANIUM
 stress(Mpa)
160
140
120
100 eliptiical
torospherical
Axis Title 80
60
40
20
0
Al-5154 Cu-alloy NITINOL TITANIUM

From all these comparisons here we got these graphs and in this TORSPHRICAL
head is better than elliptical head because it has low stress and good strength values
compare with existing model.
 Conclusion

In this project we created pressure vessel heads (ELLIPTICAL & TORISPHERICAL )

by using cad tool (creo-2) and analyses with CAE tool (Ansys workbench) in this processes the
elliptical model was existing model with cu-alloy and now here we also taken 3 different
materials those are(AL-5154, NITINOL, TITANIUM) and applied real time boundary conditions
on it.

In this processes we absorb that elliptical model with cu-alloy has been producing
139Mpa stress and other 3 materials (AL-5154& NITINOL) 141 Mpa and titanium 136Mpa
stress among all these titanium has low stress and good strength values.

And when the same boundary conditions if we apply on TORISPHERICAL head we

got less stress for all materials nearly we reduces 40% of the total stress by this change. In this all
materials got same amount of stress (102 to 103Mpa). So the stress values for all materials we
have nearby then we cannot conclude by this values only. Now we need to see safety factor also
we know that titanium is a high strength material and costly so we cannot say titanium is a
suitable material.

This time we considering nitinol & al-5154 materials both have same amount of stress
but if we use nitinol the weight will high compare to al-5154. And this al-5154 has good
weldebility characteristics also. So from all these results we can choose al-5154 material for
TORSPHERICAL head.
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