Porras - Project Report Sample 2.pdf

8/17/2019 Porras - Project Report Sample 2.pdf

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ME273

Liquid Nitrogen Evaporation Unit

Isaac Porras

Mechanical and Aerospace Engineering Department

San Jose State University

December 14, 2005

Liquid Nitrogen

Inlet

Gas OutletLiquid Nitrogen

Siphon Pump

Extrusion Absorbs

Heat from Atmosphere

to Evaporate Liquid Nitrogen

10 Slots for 10 Peliter

Thermoelectric Elements


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Executive Summary

Research in alternative energy is essential to ensure that America’s dependence on

volatile oil supplies is reduced. A possible alternative energy source can be liquid

nitrogen. Liquid nitrogen is very cold and has a boiling temperature of -196 deg C. The

vapor produced from the evaporation of liquid nitrogen expands to 700 times its original

volume. This expansion can be used to push a piston and propel an air motor. Also, a

large amount of heat is required to evaporate liquid nitrogen into a vapor. This heat

energy can be converted into electricity through the use of peltier thermoelectric

elements. The heat needed to evaporate the liquid nitrogen will be supplied by the

surrounding atmospheric air, which will heat up a large surface area heat sink extrusion.

The peltier elements will be sandwiched between the liquid nitrogen evaporator and theheat sink, which will create a temperature difference of 221 deg C and over 200 watts of

electrical energy. The electricity generated can be used to turn a DC electric motor. The

combination of air and electric motors can be used to power vehicles or other machines.

The prototype presented in this report is an evaporation unit required to turn liquid

nitrogen into gas.

The geometry is a relatively simple rectangular structure with dimensions 5.56in X

15in X 1in. The features were created by creating a 14.5in blind hole through the short

end of the rectangle. This hole is the inlet for the liquid nitrogen. Two more 2.78in blind

holes were created on the top of the structure. These holes will be used for the gas outlet

and liquid nitrogen pump. Also, ten 0.02in cavity slots were created on the surface of the

block for the ten peltier elements to fit in.

The Boundary conditions and load constraints of the model were 250 Psi on the inside,

a surface temperature of -196 deg C on the inside, a fixed screw hole in one corner with

free rotation, a heat load of 122.5 lbf*ft/sec on each peltier slot, an environment

temperature of 75 degrees, and three sides of the block were constrained with

displacement allowed in the direction of the plane. 3-D solid elements were used because

the model did not have a constant cross-sectional shape or symmetry.

The optimization of the structure was defined by maximizing the diameter of the

liquid nitrogen inlet 14.5in blind hole while keeping the safety factor under a value of


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two. The larger the diameter of the hole became, the thinner the wall of the structure

becomes, which increased the stress of the structure. A large hole is desired in order to

maximize the flow of liquid nitrogen into the device. Also, a much larger pressure of

1000 Psi was applied to the inside of the structure and the same optimization described

above was calculated.

The results show that the device is very safe at 250 Psi with a safety factor of 24. The

optimization showed that with a bore hole diameter increased to 0.9in, the safety factor

decreased to 5. This showed that the device can support a much higher pressure load and

it was found that the model can withstand up to 1000 Psi and the maximum radius hole

size for the liquid to travel through was optimized to 0.328in. Also, the thermal stress

induced by the liquid nitrogen shank the entire block by 0.082in and the temperature

distribution throughout the structure varied by 0.3 deg F. The deflection due to thermal

contraction created an extremely high stress that could destroy the structure, thus the

screws used to mount the device must allow the structure to freely expand and contract

with changes in temperature.


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Table of Contents

1. List of Tables …………………………………………………………………………..4

2. List of Figures ………………………………………………………………………..5-6

3. Project Objective ………………………………………………………………….…...7

4. Project Summary …………………………………………………………………...8-10

5. The Model Creation …………………………………………………………….…11-26

6. Analysis and Results ………………………………………………………………27-30

7. Optimization Procedure …………………………………………………………...31-36

8. Appendix ...……………………………………………………………………......37-67


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List of Tables

1. Table 1. Model Data ………………………………………………………………….. 8

2. Table 2. Results Summary for 250 Psi Load ……………..……………………………8

3. Table 3. Optimization Summary for 250 Psi Load ..…………… ..………….… ..……9

4. Table 4. Results Summary for 1000 Psi Load …………………………………...….…9

5. Table 5. Optimization Summary for 1000 Psi Load …………………………………...9

6. Table 6. Results Summary for Thermal Analysis ………………………………….....10


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List of Figures

1. Figure 1. Concept of Generating Electricity by the Flow of Heat ………………….…7

2. Figure 2. Cut-Away View of the Liquid Nitrogen Evaporator ……………..…………73. Figure 3. Isometric View of the Liquid Nitrogen Evaporator …………………..……11

4. Figure 4. Drawing of the Liquid Nitrogen Evaporator …………….…………………115. Figure 5. First Extrusion of Model ……………….……………….………………….12

6. Figure 6. Second Extrusion of Model ……………………...…………………………127. Figure 7. Third Extrusion of Model ………………………………………………..…13

8. Figure 8. Fourth Extrusion of Model …………………………………………………13

9. Figure 9. Fifth Extrusion of Model ……………………………………………...……1410. Figure 10. Sixth Extrusion of Model …………………………………………..……14

11. Figure 11. Seventh Extrusion of Model ………………………………..……………15

12. Figure 12. Load for Model ……………….……………….……………….……..….1613. Figure 13. First Constraint for Model ………………..…….…………..……………16

14. Figure 14. Second Constraint for Model ……………………….………………...…17

15. Figure 15. Third Constraint for Model ……………………………………………...1716. Figure 16. Material Selection for Model …………………………………….………1817. Figure 17. Creating FEA of the Model ………………..………………..……….…..18

18. Figure 18. Static FEA Settings ………………..………………..……..……………..19

19. Figure 19. Start Static FEA ………………………………………….………………1920. Figure 20. Creating Thermal Analysis for Model ………………….………………..20

21. Figure 21. Switching to Thermal Mode ……………….……………….………...….20

22. Figure 22. Selecting Thermal Heat Loads ……………….……………….…………2123. Figure 23. Selecting Temperature Boundary Conditions ……………….……….….21

24. Figure 24. Creating a New Thermal Analysis File ……...………….……………….22

25. Figure 25. Configuring the Thermal Analysis ………………………………………22

26. Figure 26. Start Thermal Analysis …..…………………..…………………..………2327. Figure 27. Creating the Thermal Stress Analysis ……..……………………….……23

28. Figure 28. Switching Back to Structure Mode …..………………………..……...…24

29. Figure 29. Setting the Ambient Temperature ……………………..……….………..2430. Figure 30. Creating a New Thermal Stress Analysis File …………..……….......….25

31. Figure 31. Thermal Stress Analysis Settings …..…………..………………..………25

32. Figure32. Start Thermal Stress Analysis ……..………………..……..……………..2633. Figure 33. FEA Displacement and Stress Fringe Plots ……………..…….…...…....27

34. Figure 34. FEA Von Misses and Strain Energy vs. P-Loop Pass ……..….……........28

35. Figure 35. Thermal Stress Displacement and Stress Fringe Plots ………………..…2836. Figure 36. Thermal Stress Analysis Mass and Strain Energy vs. P-Loop Pass ……..29

37. Figure 37. Thermal Analysis Temperature Fringe Plot ……………………..………2938. Figure 38. Creating Optimization ……….……….……….……….……….………. 31

39. Figure 39. Creating a Design Parameter ….……….……….………….……….……3240. Figure 40. Selecting a Design Parameter …..………………..…..…………………..32

41. Figure 41. Creating a New Design Study File ……..…………….………………….33

42. Figure 42. Opening the Design Study Parameter Window …………….………....…3343. Figure 43. Creating the Design Study Parameters ………….………………….……34

44. Figure 44. Start Design Study ……….……….…….…………….…………….……34


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45. Figure 45. Optimization Mass and Stress vs. Pass Graph ………….………………..35

46. Figure 46. Optimized Model ……….………………….………………….…………35


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Project Objective

The objective of this project is to create a liquid nitrogen evaporator that will

withstand both a maximum pressure of 250 Psi and a temperature of -196 deg. C, and

with a size of 5.56in X 15in X 1in. This device will transform the heat used to evaporate

liquid nitrogen inside the aluminum block into electricity with the use of ten peltier

thermoelectric elements attached to the surface of the aluminum block, which turns heat

flow into electric energy (see below). The pressure created from this evaporation will

then be stored in an external tank and used to turn an air motor. This project will,

however, only focus on the device that will evaporate the liquid nitrogen up to 250 Psi.

The size of this evaporator is to be minimized in order to power a small vehicle like a go

kart or golf cart.

Figure 1. Concept of Generating Electricity by the Flow of Heat

Figure 2. Cut-Away View of the Liquid Nitrogen Evaporator

Liquid Nitrogen

Inlet

Gas OutletLiquid Nitrogen

Siphon Pump


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Project Summary

Table 1. Model Data

Model Data

Model Type: (3-D, Plane Stress, Plane

Strain, or Axisymmetric) 3-D

Elements Type: (Beam, 2-D shell,compressed shell, axisymmetric 1-D shell,

etc.)

Solid

Constraints: (where applied: surface ,

edge/curve, points; exact location, andDOF that are fixed)

A fixed screw hole in one corner with free

rotation, three sides of the block wereconstrained with displacement allowed in

the direction of the plane.

Load: (Type of load, where applied:

surface , edge/curve, points; exact location,and magnitudes of load

250 Psi on the inside, a surface temperature

of -196 deg C on the inside, a heat load of122.5 lbf*ft/sec on each peltier slot, an

environment temperature of 75 degrees,

Material Properties

Aluminum 6061

Yield Strength = 37kPsi

Density 0.0002536 [lbf sec^2 / in^4]

Young's Modulus 1e+07 [lbf / in^2]

Poisson's Ratio 0.3

Conductivity 22.49 [lbf / (sec F)]

Specific Heat 829900 [in^2 / (sec^2 F)]

Thermal Expansion 1.3e-05 [/ F]

Shear Stiffness 3.84615e+06 [lbf / in^2]

Units used IPS

Table 2. Results Summary for 250 Psi Load

Results Summary for 250 Psi Load

Maximum static stress: 1.5 kPsi

Yield Strength of the material: 37 kPsi

Maximum deflection in the model: 0.000029in

Factor of safety 24

Total number of elements used and theirtypes:

5190 Solid Elements

Total CPU run time: 1623.51 sec

• Using the 3-D solid elements took a very ling time and the school computers werenot powerful enough to compute the FEA. After, using a more powerful

computer, no problems were encountered in the FEA.


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Table 3. Optimization Summary for 250 Psi Load

Optimization Summary for 250 Psi Load

Optimized Parameters: Liquid Nitrogen Inlet Hole DiameterMin: 0.25in

Max: 0.45inOptimization Goal: Minimize Von Misses Stress

Limits: Von Misses Stress < 19500 Psi

= Safety Factor of 1.9 or more

A Comparison of the New and Optimized

Parameters:

The original radius was 0.25in. The

optimal radius was found to be the

maximum 0.45in radius with a safety factorof 5.


Table 4. Results Summary for 1000 Psi LoadResults Summary for 1000 Psi LoadMaximum static stress: 6.02 kPsi



Factor of safety 6

Total number of elements used and theirtypes:

5190 Solid Elements


• Using the 3-D solid elements took a very ling time and the school computers werenot powerful enough to compute the FEA. After, using a more powerful

computer, no problems were encountered in the FEA.

Table 5. Optimization Summary for 1000 Psi Load

Optimization Summary for 1000 Psi Load

Optimized Parameters: Liquid Nitrogen Inlet Hole Diameter

Min: 0.25inMax: 0.45in

Optimization Goal: Minimize Von Misses Stress

Limits: Von Misses Stress < 19500 PsiFor a Safety Factor of 1.9 or more

A Comparison of the New and OptimizedParameters:

The original radius was 0.25in. Theoptimal radius was found to be the

maximum 0.328in radius with a safety

factor of 1.9.



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Table 6. Results Summary for Thermal Analysis

Results Summary for Thermal AnalysisTemperature Distribution: Min: -320.46 deg F

Max: -320.80 deg F



Factor of safety 5

Total number of elements used and their

types:

5190 Solid Elements



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The Model Creation

Pro/E:

Figure 3. Isometric View of the Liquid Nitrogen Evaporator

Figure 4. Drawing of the Liquid Nitrogen Evaporator

The model is very straightforward to create. Start with a rectangular block with the

overall dimension shown above. Then create the holes and recess cut-outs in the locations

shown in the print. Use Aluminum 6061 material for the model. The following figures are


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screen shots of the extrusion steps for creating the model. Make sure IPS units is selected.

Please refer to drawing Figure 4 in previous page for detailed dimensions:

1) Extrude the solid rectangle with overall dimensions 5.56 X 15 X 1

Figure 5. First Extrusion of Model

2) Extrude cut the Liquid Nitrogen inlet blind hole.

Figure 6. Second Extrusion of Model


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3) Extrude cut both gas and pump holes.

Figure 7. Third Extrusion of Model

4) Extrude cut the peltier thermoelectric element recess.

Figure 8. Fourth Extrusion of Model


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5) Right-click the previous extrusion in the Tree window and select the pattern command

to create two rows of five recesses.

Figure 9. Fifth Extrusion of Model

6) Extrude cut the mounting hole in one corner.

Figure 10. Sixth Extrusion of Model


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7) Right-click the previous extrusion in the Tree window and select the pattern command

to create two rows of three holes. The model is complete.

Figure 11. Seventh Extrusion of Model

Pro/M:

The model type used is 3-D solid elements. 3-D elements were used because there was

no constant cross-sectional geometry and there was no symmetry. No idealizations wereused in this model. The two magnitudes of the loads used were pressure loads of 250 Psi

and 1000 Psi. The 1000 Psi load will be used in the following Pro/M procedure

explanation. Steps for creating the loads, constraints, materials, thermal constraints, and

analysis will be discussed in the following figures:


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1) Click on the “New Pressure Load” button, hold the Cntrl key and select the red areas

inside model. Release the Cntrl key and click the middle mouse button. Then type a value

of 1000 Psi and click “Ok.”

Figure 12. Load for Model

2) Click on the “New Displacement Constraint” button, hold the Cntrl key and select the

10 red areas where the peltier recesses are. Release the Cntrl key and click the middle

mouse button. Then set the X and Y translation to “Free” and click ok.

Figure 13. First Constraint for Model


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red area on the front side of the structure. Release the Cntrl key and click the middle

mouse button. Then set the Y and Z translation to “Free” and click ok.

Figure 14. Second Constraint for Model


bottom of the structure. Release the Cntrl key and click the middle mouse button. Then

set the X and Z translation to “Free” and click ok.

Figure 15. Third Constraint for Model


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4) Click on the “Define Material” button and click on AL6061. Press the “>>>” button

and click the “Assign” button. Select the “Part” selection and click on the structure. Then

click the “Close” button.

Figure 16. Material Selection for Model

5) Click on the “Analysis and Design Studies” button, click the “File” menu button, and

then select the “New Static” menu item.

Figure 17. Creating FEA of the Model


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6) Select the “Multi-Pass Adaptive” selection in the Method menu, then change the

maximum polynomial order to 9 and click “Ok.”

Figure 18. Static FEA Settings

7) Click “Start Run” button and wait for the FEA to complete.

Figure 19. Start Static FEA


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8) After the FEA is complete, the thermal loads and constraints can be added. Click on

“Edit” in the menu and select “Mechanica Model Type.”

Figure 20. Creating Thermal Analysis for Model

9) Change the Mode to “Thermal” and click “Ok.”

Figure 21. Switching to Thermal Mode


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10) Select the “New Heat Load on Surface” button, hold down the Cntrl key and select

the 10 red shaded areas where the 10 peltier element recesses are. Release the “Cntrl”

button and click the middle mouse button. Then type 122.5 lbf*ft/sec in the Q section andclick “Ok.”

Figure 22. Selecting Thermal Heat Loads

11) Click the “New Prescribed Temperature” button, hold down the Cntrl key and select

the red shaded areas on the inside of the structure. Release the Cntrl key and click themiddle mouse button. Then type -321.8 deg F in the temperature section to simulate the

liquid nitrogen inside the structure and click “Ok.”

Figure 23. Selecting Temperature Boundary Conditions


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12) Click on the “Analysis and Design Studies” button, click “File” from the menu, and

select the “New Steady State Thermal” menu item.

Figure 24. Creating a New Thermal Analysis File

13) Select the “Multi-Pass Adaptive” selection in the Method menu, then change the

maximum polynomial order to 9 and click “Ok.”

Figure 25. Configuring the Thermal Analysis


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14) Click “Start Run” button and wait for the thermal analysis to complete.

Figure 26. Start Thermal Analysis

15) Once the thermal analysis is complete, the thermal stress analysis can begin. Click“Edit” button in the menu and select “Mechanical Model Type.”

Figure 27. Creating the Thermal Stress Analysis


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16) Select “Structure” from the Mode section and click “Ok.”

Figure 28. Switching Back to Structure Mode

17) Click “Insert” from the Menu, select the “MECT/T” menu item, type 75 deg F in theReference Temperature section to simulate ambient air temperature, and click “Ok.”

Figure 29. Setting the Ambient Temperature


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18) Click on the “Analysis and Design Studies” button, click “File” from the menu, and

select the “New Static” menu item.

Figure 30. Creating a New Thermal Stress Analysis File

19) Select the “Multi-Pass Adaptive” selection in the Method menu, then change themaximum polynomial order to 9 and click “Ok.”

Figure 31. Thermal Stress Analysis Settings


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20) Click “Start Run” button and wait for the thermal FEA to complete.

Figure32. Start Thermal Stress Analysis


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Analysis and Results

Static:

max_disp_mag: 1.162636e-04 0.3%

max_stress_vm: 6.019675e+03 0.2%

Thermal:

max_disp_mag: 8.242551e-02 0.0%

max_stress_vm: 6.596068e+03 0.0%

max_temperature: -3.204613e+02 0.0%min_temperature: -3.208000e+02 0.0%

(See Appendix for Complete Analysis RPT Results)

Figure 33. FEA Displacement and Stress Fringe Plots


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Figure 34. FEA Von Misses and Strain Energy vs. P-Loop Pass

Figure 35. Thermal Stress Displacement and Stress Fringe Plots


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Figure 36. Thermal Stress Analysis Mass and Strain Energy vs. P-Loop Pass

Figure 37. Thermal Analysis Temperature Fringe Plot


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The results showed that the most stress is created by the thermal stress and not by the

pressure load. The results took over a day to complete the analysis because 3-D solid

elements were used and over 5000 elements were used. Also, the thermal analysis

showed that the temperature variation is relatively constant throughout the structure even

though the liquid nitrogen only touches the inside surface of the inlet center hole and with

nearly 3000 watts of total heat flow through the surface of the peltier recesses.

The analysis showed that the objectives of this project were met and exceeded. The

structure withstood over four times the original required load with a safety factor greater

than two. However, because of the large contraction deflection of the structure due the

extremely cold temperatures in the center of the structure, the structure must be allowed

to expand and contract freely or else the structure will be destroyed. The results of the

analysis seemed to be very realistic and accurate. Real-life testing of this design can be

used to verify the results.


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Optimization Procedure

The design parameters for the optimization was to maximize the diameter of the liquid

nitrogen inlet blind hole in order to allow the maximum amount of liquid nitrogen to flow

into the structure while keeping the safety factor greater or equal to 1.9. Steps for

completing the optimization will be shown in the following figures:

1) Select “Analysis” from the menu and select the “Mechanica Design Controls” menu

item.

Figure 38. Creating Optimization


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2) Select “Design Params” from the menu and click the “Create” button.

Figure 39. Creating a Design Parameter

3) Select the 0.25 radius dimension and click the middle mouse button. Then click

“Done/Return” from the menu.

Figure 40. Selecting a Design Parameter


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4) Click the “Analysis and Design Studies” button, click “File” from the menu, and select

the “New Design Study” menu item.

Figure 41. Creating a New Design Study File

5) Select “Optimization” from the Type menu.

Figure 42. Opening the Design Study Parameter Window


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6) Check the Goal section, click “Select,” choose “max_stress_vm” from the menu and

click “Ok.” Then check the Limits On section and click “Create,” select

“max_stress_vm” from the menu and click “Ok.” Select the “>” sign and type 19500 Psiin the limit sub-window. Then check the item in the Parameter window, select

“Minimum” in the Min section, “Maximum” in the Init section, and “Maximum” in the

Max section. Lastly, uncheck the “Repeat P-Loop Convergence” and click “Accept.”

Figure 43. Creating the Design Study Parameters

7) Click “Start Run” button and wait for the thermal analysis to complete.

Figure 44. Start Design Study


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The following figures are the results of the optimization:

Figure 45. Optimization Mass and Stress vs. Pass Graph

Figure 46. Optimized Model


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A large hole is desired to maximize the flow of liquid nitrogen into the liquid nitrogen

evaporator. However, if the size of the hole is too large, then the wall thickness of the

structure will decrease, which will increase the stress and possibly destroy the structure

with a 1000 Psi load. The optimization began with a maximum an initial radius of 0.45in.

The computer then decreased the radius of the liquid nitrogen inlet blind hole until the

safety factor reached a value of more than 1.9. As the radius decreased, the mass

increased and the stress decreased. There was some trouble with the optimization,

because the optimized radius of 0.328 was found after the first run. After the first run, the

optimization produced an error and crashed. The optimization did not successfully

complete, but before the optimization crashed, the data was saved. The incomplete RPT

file showed that the final optimized radius was the correct value because the Von Misses

stress calculated at the optimized diameter made a safety factor of 1.92, which is only

slightly higher that 1.9. Thus, the optimization RPT data is still useful information, even

though the value was found after the first run and crashed.


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Appendix

a. Project Proposal

b. Project Research

f. Edited *.rpt files


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Liquid Nitrogen Evaporation Unit

Team Member:

Isaac Porras

11/3/05


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Objective:

The objective of this project is to create a liquid nitrogen evaporator that willwithstand both a maximum pressure of 300 psi and a temperature of -196 deg. C, and

with a size of about 5in X 5in X 1in. This device will be used to generate electricity with

the use of peltier elements (see figure below), which turn heat flow into electric energy.The pressure created from this evaporation will then be used to turn an air motor. This

project will, however, only focus on the device that will evaporate the liquid nitrogen up

to 300 psi. The size of this evaporator is to be minimized in order to power a small

vehicle like a go kart or golf cart.

Figure 1. Concept of Generating Electricity by the Flow of Heat

(See Detailed Design Sketch on Next Page)


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Procedure:

The procedure to complete this project is to first model an aluminum block with

the appropriate holes for liquid nitrogen to travel, mounting holes, a groove to fit a peltierdevice, holes for liquid nitrogen level sensors, and holes for temperature sensors. 3-D

elements will then be used to analyze the 300psi pressure and -196 deg. C temperature

inside the vessel. Then the safety factor will be calculated and the device will be

optimized to minimize mass. A heat-sink will then be attached to the bottom of theevaporator increase the heat-flow into the evaporator.

End Product Deliverables:

A liquid nitrogen evaporator that has:

1. Minimized mass2. Safety factor ≥23. Ability to mount two peltier elements

4. Ability to mount to a heat-sink to increase heat flow into the evaporator5. Ability to mount temperature sensors

6. Ability to mount liquid nitrogen level sensors

7. Ability to mount Pressure sensors

8. Ability to withstand Thermal Stress

Timetable:

October 24 through December 12Oct Nov Dec

Week/Task 24 31 7 14 21 28 5 12

1. Prepare Proposal

2. Initial Design

3. Part FEA analysis

4. Part Optimization

5. Assembly

6. Drawings

7. Analysis

8. Final Report


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------------------------------------------------------------

Mechanica Structure Version K-01-27:spg

Summary for Design Study "psi1000_static"Sat Dec 10, 2005 23:35:53

------------------------------------------------------------

Run Settings

Memory allocation for block solver: 1000.0

Parallel Processing StatusParallel task limit for current run: 2

Parallel task limit for current platform: 64

Number of processors detected automatically: 2Checking the model before creating elements...

These checks take into account the fact that AutoGEM will

automatically create elements in volumes with material

properties, on surfaces with shell properties, and on curveswith beam section properties.

Generate elements automatically.Checking the model after creating elements...

No errors were found in the model.

Mechanica Structure Model Summary

Principal System of Units: Inch Pound Second (IPS)

Length: inForce: lbf

Time: sec

Temperature: F

Model Type: Three Dimensional

Points: 1762Edges: 8559

Faces: 11980

Springs: 0

Masses: 0

Beams: 0

Shells: 0Solids: 5190

Elements: 5190


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------------------------------------------------------------

Standard Design Study

Static Analysis "psi1000_static":

Convergence Method: Multiple-Pass Adaptive

Plotting Grid: 4

Convergence Loop Log: (23:36:05)

>> Pass 1 > Pass 7


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---------------- ------------ -----------------

LoadSet1 1.36e+02 1.8% of 7.34e+03

Resource Check (00:02:15)

Elapsed Time (sec): 1581.95

CPU Time (sec): 1628.16Memory Usage (kb): 1216297

Wrk Dir Dsk Usage (kb): 2634752

The analysis converged to within 10% onedge displacement, element strain energy,

and global RMS stress.

Total Mass of Model: 2.000164e-02

Total Cost of Model: 0.000000e+00

Constraint Set: ConstraintSet1

Load Set: LoadSet1

Resultant Load on Model:

in global X direction: 4.148195e-03in global Y direction: -3.927022e+02

in global Z direction: -2.804163e-02

Measures:

Name Value Convergence-------------- ------------- -----------

max_beam_bending: 0.000000e+00 0.0%

max_beam_tensile: 0.000000e+00 0.0%

max_beam_torsion: 0.000000e+00 0.0%max_beam_total: 0.000000e+00 0.0%

max_disp_mag: 1.162636e-04 0.3%

max_disp_x: 4.990149e-05 0.3%max_disp_y: 5.065681e-05 0.6%

max_disp_z: -1.149555e-04 0.4%

max_prin_mag: -7.341313e+03 14.8%max_rot_mag: 0.000000e+00 0.0%

max_rot_x: 0.000000e+00 0.0%

max_rot_y: 0.000000e+00 0.0%

max_rot_z: 0.000000e+00 0.0%max_stress_prin: 5.903367e+03 10.1%

max_stress_vm: 6.019675e+03 0.2%

max_stress_xx: -2.443959e+03 12.3%


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max_stress_xy: 9.118155e+02 8.6%

max_stress_xz: -3.144181e+03 13.1%

max_stress_yy: -2.978996e+03 13.4%max_stress_yz: -2.714660e+03 15.7%

max_stress_zz: -6.207449e+03 11.1%

min_stress_prin: -7.341313e+03 14.8%strain_energy: 6.773170e-01 0.2%

Analysis "psi1000_static" Completed (00:02:17)

------------------------------------------------------------

Memory and Disk Usage:

Machine Type: Windows NT/x86

RAM Allocation for Solver (megabytes): 1000.0

Total Elapsed Time (seconds): 1585.01

Total CPU Time (seconds): 1629.03

Maximum Memory Usage (kilobytes): 1216297Working Directory Disk Usage (kilobytes): 2634752

Results Directory Size (kilobytes):81676 .\psi1000_static

Maximum Data Base Working File Sizes (kilobytes):1048576 .\psi1000_static.tmp\kblk1.bas

832512 .\psi1000_static.tmp\kblk2.bas

668672 .\psi1000_static.tmp\kel1.bas84992 .\psi1000_static.tmp\oel1.bas

------------------------------------------------------------

Run Completed

Sun Dec 11, 2005 00:02:18


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Steady-State Thermal Analysis "me273_project_thermal":

Convergence Method: Multiple-Pass AdaptivePlotting Grid: 4


>> Pass 1 > Pass 2


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>> Pass 3 > Pass 4 > Pass 5


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Local Temp/Energy Index: 8.1%

Global Energy Index: 3.3%

Resource Check (16:26:04)Elapsed Time (sec): 67.79

CPU Time (sec): 60.42

Memory Usage (kb): 1134205Wrk Dir Dsk Usage (kb): 34816

>> Pass 6


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Name Value Convergence

-------------- ------------- -----------

energy_norm: 1.434345e+01 0.0%max_flux_mag: 4.615338e+01 1.4%

max_flux_x: -2.400180e+01 0.5%

max_flux_y: -3.243341e+01 0.0%max_flux_z: 2.531674e+01 1.2%

max_grad_mag: 2.052174e+00 1.4%

max_grad_x: 1.067221e+00 0.5%

max_grad_y: 1.442126e+00 0.0%max_grad_z: -1.125689e+00 1.2%

max_temperature: -3.204613e+02 0.0%

min_temperature: -3.208000e+02 0.0%

Analysis "me273_project_thermal" Completed (16:26:25)

------------------------------------------------------------







Results Directory Size (kilobytes):43454 .\me273_project_thermal

Maximum Data Base Working File Sizes (kilobytes):

34816 .\me273_project_thermal.tmp\kel1.bas

------------------------------------------------------------

Run Completed

Sat Dec 10, 2005 16:26:25


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------------------------------------------------------------


Mechanica Thermal Version K-01-27:spgSummary for Design Study "Trial1"

Sat Dec 10, 2005 18:23:05

------------------------------------------------------------

Run Settings


Parallel Processing Status

Parallel task limit for current run: 2

Parallel task limit for current platform: 64 Number of processors detected automatically: 2

Checking the model before creating elements...


automatically create elements in volumes with material properties, on surfaces with shell properties, and on curves

with beam section properties.

Generate elements automatically.

Checking the model after creating elements...




Length: in

Force: lbf

Time: sec

Temperature: F


Points: 1762

Edges: 8559

Faces: 11980

Springs: 0

Masses: 0

Beams: 0Shells: 0

Solids: 5190


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Elements: 5190

------------------------------------------------------------

Mechanica Thermal Model Summary


Length: in

Force: lbfTime: sec

Temperature: F


Points: 1762

Edges: 8559Faces: 11980

Beams: 0Shells: 0

Solids: 5190

Elements: 5190

------------------------------------------------------------


Analyses:

Trial1

me273_project_thermal

Analysis Trial1 requires input data from

analysis me273_project_thermal.

Static Analysis "Trial1":

Convergence Method: Multiple-Pass AdaptivePlotting Grid: 4


>> Pass 1


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Maximum Edge Order: 1

Solving Equations (18:24:44)

Post-Processing Solution (18:24:45)Calculating Disp and Stress Results (18:24:45)

Checking Convergence (18:25:33)

Elements Not Converged: 5190Edges Not Converged: 8559

Local Disp/Energy Index: 100.0%

Global RMS Stress Index: 100.0%

Resource Check (18:25:34)Elapsed Time (sec): 148.73

CPU Time (sec): 95.28

Memory Usage (kb): 1134269Wrk Dir Dsk Usage (kb): 40960

>> Pass 4


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Load Set: LoadSet1


in global X direction: 6.763373e-03

in global Y direction: -9.816023e+01


Measures:

Name Value Convergence

-------------- ------------- -----------


max_beam_tensile: 0.000000e+00 0.0%max_beam_torsion: 0.000000e+00 0.0%

max_beam_total: 0.000000e+00 0.0%

max_disp_mag: 8.242551e-02 0.0%max_disp_x: -7.715425e-02 0.0%

max_disp_y: -2.860447e-02 0.0%

max_disp_z: 5.050752e-03 0.0%max_prin_mag: -6.025085e+03 0.0%

max_rot_mag: 0.000000e+00 0.0%

max_rot_x: 0.000000e+00 0.0%max_rot_y: 0.000000e+00 0.0%

max_rot_z: 0.000000e+00 0.0%

max_stress_prin: 4.387434e+03 0.0%max_stress_vm: 6.596068e+03 0.0%

max_stress_xx: -5.548722e+03 0.0%

max_stress_xy: 2.199788e+03 0.0%

max_stress_xz: -1.611881e+03 0.0%max_stress_yy: -4.827445e+03 0.0%

max_stress_yz: -1.935812e+03 0.0%

max_stress_zz: 2.948472e+03 0.0%min_stress_prin: -6.025085e+03 0.0%

strain_energy: 3.502546e-01 0.0%

Analysis "Trial1" Completed (18:28:40)

------------------------------------------------------------




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Total Elapsed Time (seconds): 334.92Total CPU Time (seconds): 169.97

Maximum Memory Usage (kilobytes): 1164631

Working Directory Disk Usage (kilobytes): 43008

Results Directory Size (kilobytes):

85845 .\Trial1

Maximum Data Base Working File Sizes (kilobytes):

22528 .\Trial1.tmp\kel1.bas

20480 .\Trial1.tmp\oel1.bas

------------------------------------------------------------

Run Completed

Sat Dec 10, 2005 18:28:40


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------------------------------------------------------------


Summary for Design Study "psi1000_optimization"Sun Dec 11, 2005 12:18:02

------------------------------------------------------------

Run Settings


Perform mesh smoothing after each parameter update.

Remesh after each parameter update.

Parallel Processing Status

Parallel task limit for current run: 2Parallel task limit for current platform: 64

Number of processors detected automatically: 2

Checking the model before creating elements...

These checks take into account the fact that AutoGEM willautomatically create elements in volumes with material

properties, on surfaces with shell properties, and on curves

with beam section properties.

Generate elements automatically.

Checking the model after creating elements...




Length: in

Force: lbf

Time: secTemperature: F


Points: 1762

Edges: 8559Faces: 11980

Springs: 0

Masses: 0Beams: 0

Shells: 0

Solids: 5190


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Elements: 5190

------------------------------------------------------------

Optimization Design Study

Using Gradient Projection Optimization Algorithm

Sun Dec 11, 2005 12:18:09

Goal

Analysis: psi1000_static

Load Set: LoadSet1Minimize: max_stress_vm

Limit: 1

Analysis: psi1000_staticLoad Set: LoadSet1

max_stress_vm < 1.9500e+004

Parameter Min. Value Initial Value Max. Value

d8 0.25 0.45 0.45

Optimization Convergence Tolerance: 1 %

Maximum Number of Optimization Iterations: 20

Begin Analysis of Goal and Limits of (12:18:09)

Initial Design

** Warning: Analysis did not converge during optimization because max polynomial order of 9 was reached.

Local Disp/Energy Index: 24.5%

Global RMS Stress Index: 11.0%

------------------------------------------------------------

Initial Design Status

Parameters:d8 0.45

Status of Optimization Limits:

1. max_stress_vm 4.9694e+04 < 1.9500e+04 (VIOLATED)

The initial design violates the optimization limits.

Begin search for feasible values of (13:21:30)

parameters.


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Begin Optimization Iteration 1 (13:21:30)

Initial Goal: 4.9694e+04

Fixing Optimization Limit (13:21:30)1 (max_stress_vm)

Parameters:

d8 0.360707Status of Optimization Limit: 1

max_stress_vm 2.4484e+04 < 1.9500e+04 (VIOLATED)

Parameters:

d8 0.328472

Status of Optimization Limit: 1

max_stress_vm 1.9196e+04 < 1.9500e+04 (satisfied)


1. max_stress_vm 1.9196e+04 < 1.9500e+04 (satisfied)

The parameter values are now feasible.

Result of Optimization Iteration 1

Parameters:

d8 0.328472Goal: 1.9196e+04








Begin Line Search (14:29:13)Step size governed by lower limit on

parameter d8

Line Search Iteration 1

Parameters:

d8 0.324548


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Goal: 1.9056e+04

Parameters:d8 0.322331

Goal: 1.8941e+04

Parameters:

d8 0.25

Goal: 1.5271e+04

** Warning: Changing the parameters has produced invalidmodel or geometry for the following parameter

values:

Parameters:

d8 0.252

Recovering from invalid parameter values by cutting

step size.


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------------------------------------------------------------


Summary for Design Study "me273_project_static"Sat Dec 10, 2005 15:50:57

------------------------------------------------------------

Run Settings




Number of processors detected automatically: 2Checking the model before creating elements...








Length: inForce: lbf

Time: sec

Temperature: F



Faces: 11980

Springs: 0

Masses: 0

Beams: 0


Elements: 5190


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------------------------------------------------------------


Static Analysis "me273_project_static":

Convergence Method: Multiple-Pass Adaptive

Plotting Grid: 4


>> Pass 1 > Pass 7


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---------------- ------------ -----------------

LoadSet1 3.39e+01 1.8% of 1.84e+03





The analysis converged to within 10% onedge displacement, element strain energy,

and global RMS stress.

Total Mass of Model: 2.000164e-02



Load Set: LoadSet1


in global X direction: 1.037049e-03in global Y direction: -9.817556e+01


Measures:

Name Value Convergence-------------- ------------- -----------


max_beam_tensile: 0.000000e+00 0.0%

max_beam_torsion: 0.000000e+00 0.0%max_beam_total: 0.000000e+00 0.0%

max_disp_mag: 2.906589e-05 0.3%

max_disp_x: 1.247537e-05 0.3%max_disp_y: 1.266420e-05 0.6%

max_disp_z: -2.873888e-05 0.4%

max_prin_mag: -1.835328e+03 14.8%max_rot_mag: 0.000000e+00 0.0%

max_rot_x: 0.000000e+00 0.0%

max_rot_y: 0.000000e+00 0.0%

max_rot_z: 0.000000e+00 0.0%max_stress_prin: 1.475842e+03 10.1%

max_stress_vm: 1.504919e+03 0.2%

max_stress_xx: -6.109898e+02 12.3%


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max_stress_xy: 2.279539e+02 8.6%

max_stress_xz: -7.860452e+02 13.1%

max_stress_yy: -7.447491e+02 13.4%max_stress_yz: -6.786650e+02 15.7%

max_stress_zz: -1.551862e+03 11.1%

min_stress_prin: -1.835328e+03 14.8%strain_energy: 4.233231e-02 0.2%

Analysis "me273_project_static" Completed (16:17:33)

------------------------------------------------------------







Results Directory Size (kilobytes):81652 .\me273_project_static

Maximum Data Base Working File Sizes (kilobytes):1048576 .\me273_project_static.tmp\kblk1.bas

832512 .\me273_project_static.tmp\kblk2.bas

668672 .\me273_project_static.tmp\kel1.bas84992 .\me273_project_static.tmp\oel1.bas

------------------------------------------------------------

Run Completed

Sat Dec 10, 2005 16:17:34


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------------------------------------------------------------


Mechanica Thermal Version K-01-27:spgSummary for Design Study "optimization"

Sat Dec 10, 2005 20:29:18

------------------------------------------------------------

Run Settings


Perform mesh smoothing after each parameter update.Remesh after each parameter update.



Number of processors detected automatically: 2

Checking the model before creating elements...These checks take into account the fact that AutoGEM will







Length: in

Force: lbfTime: sec

Temperature: F



Faces: 11980

Springs: 0Masses: 0

Beams: 0

Shells: 0


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Solids: 5190

Elements: 5190

------------------------------------------------------------

Mechanica Thermal Model Summary


Length: in

Force: lbf

Time: secTemperature: F


Points: 1762

Edges: 8559

Faces: 11980

Beams: 0


Elements: 5190

------------------------------------------------------------

Optimization Design Study

Using Gradient Projection Optimization Algorithm

Sat Dec 10, 2005 20:29:25

Goal

Analysis: me273_project_staticLoad Set: LoadSet1

Minimize: max_stress_vm

Limit: 1

Analysis: me273_project_static

Load Set: LoadSet1

max_stress_vm < 1.9500e+004

Parameter Min. Value Initial Value Max. Value

d8 0.25 0.45 0.45


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Optimization Convergence Tolerance: 1 %

Maximum Number of Optimization Iterations: 20

Begin Analysis of Goal and Limits of (20:29:25)

Initial Design** Warning: Analysis did not converge during optimization

because max polynomial order of 9 was reached.

Local Disp/Energy Index: 11.9%Global RMS Stress Index: 0.3%

------------------------------------------------------------

Initial Design Status

Parameters:d8 0.45



Goal (before optimization): 6.6134e+03






Optimization converged on limit boundary.

Best Design Found:

Parameters:

d8 0.45Goal: 6.6134e+03

Optimization study statistics: Number of Base Analyses: 5

Number of Perturbation Analyses: 2

------------------------------------------------------------



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Total Elapsed Time in Parameter Updates (seconds):

122.23

Total Engine Elapsed Time Minus Param. Updates (seconds):1053.51

Total CPU Time in Parameter Updates (seconds):

57.80Total Engine CPU Time Minus Param. Updates (seconds):

815.50

Results Directory Size (kilobytes):118127 .\optimization

Maximum Data Base Working File Sizes (kilobytes):192512 .\optimization.tmp\kel1.bas

40960 .\optimization.tmp\oel1.bas

------------------------------------------------------------

Run Completed

Sat Dec 10, 2005 20:48:53

Porras - Project Report Sample 2.pdf

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Transcript of Porras - Project Report Sample 2.pdf