Porras - Project Report Sample 2.pdf
Transcript of 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.
Total CPU run time: 815.5 sec
Table 4. Results Summary for 1000 Psi LoadResults Summary for 1000 Psi LoadMaximum static stress: 6.02 kPsi
Yield Strength of the material: 37 kPsi
Maximum deflection in the model: 0.000029in
Factor of safety 6
Total number of elements used and theirtypes:
5190 Solid Elements
Total CPU run time: 1629.03 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.
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.
Total CPU run time: 4667.81 sec
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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
Yield Strength of the material: 37 kPsi
Maximum deflection in the model: 0.082in
Factor of safety 5
Total number of elements used and their
types:
5190 Solid Elements
Total CPU run time: 1629.03 sec
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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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3) Click on the “New Displacement Constraint” button, hold the Cntrl key and select the
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
4) Click on the “New Displacement Constraint” button, hold the Cntrl key and select the
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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Standard Design Study
Steady-State Thermal Analysis "me273_project_thermal":
Convergence Method: Multiple-Pass AdaptivePlotting Grid: 4
Convergence Loop Log: (16:25:08)
>> 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)
------------------------------------------------------------
Memory and Disk Usage:
Machine Type: Windows NT/x86
RAM Allocation for Solver (megabytes): 1000.0
Total Elapsed Time (seconds): 88.90
Total CPU Time (seconds): 77.63
Maximum Memory Usage (kilobytes): 1134205Working Directory Disk Usage (kilobytes): 34816
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 Structure Version K-01-27:spg
Mechanica Thermal Version K-01-27:spgSummary for Design Study "Trial1"
Sat Dec 10, 2005 18:23:05
------------------------------------------------------------
Run Settings
Memory allocation for block solver: 1000.0
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...
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 curves
with 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: in
Force: lbf
Time: sec
Temperature: F
Model Type: Three Dimensional
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
Principal System of Units: Inch Pound Second (IPS)
Length: in
Force: lbfTime: sec
Temperature: F
Model Type: Three Dimensional
Points: 1762
Edges: 8559Faces: 11980
Beams: 0Shells: 0
Solids: 5190
Elements: 5190
------------------------------------------------------------
Standard Design Study
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
Convergence Loop Log: (18:24:39)
>> 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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Total Cost of Model: 0.000000e+00
Constraint Set: ConstraintSet1
Load Set: LoadSet1
Resultant Load on Model:
in global X direction: 6.763373e-03
in global Y direction: -9.816023e+01
in global Z direction: -2.757513e-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: 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)
------------------------------------------------------------
Memory and Disk Usage:
Machine Type: Windows NT/x86
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RAM Allocation for Solver (megabytes): 1000.0
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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------------------------------------------------------------
Mechanica Structure Version K-01-27:spg
Summary for Design Study "psi1000_optimization"Sun Dec 11, 2005 12:18:02
------------------------------------------------------------
Run Settings
Memory allocation for block solver: 1000.0
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...
No errors were found in the model.
Mechanica Structure Model Summary
Principal System of Units: Inch Pound Second (IPS)
Length: in
Force: lbf
Time: secTemperature: F
Model Type: Three Dimensional
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)
Status of Optimization Limits:
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
Status of Optimization Limits:
1. max_stress_vm 1.9196e+04 < 1.9500e+04 (satisfied)
Resource Check (14:29:12)
Elapsed Time (sec): 7870.63
CPU Time (sec): 4667.81Memory Usage (kb): 1394744
Wrk Dir Dsk Usage (kb): 3554304
Begin Optimization Iteration 2 (14:29:12)
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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------------------------------------------------------------
Mechanica Structure Version K-01-27:spg
Summary for Design Study "me273_project_static"Sat Dec 10, 2005 15:50:57
------------------------------------------------------------
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 "me273_project_static":
Convergence Method: Multiple-Pass Adaptive
Plotting Grid: 4
Convergence Loop Log: (15:51:10)
>> Pass 1 > Pass 7
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---------------- ------------ -----------------
LoadSet1 3.39e+01 1.8% of 1.84e+03
Resource Check (16:17:30)
Elapsed Time (sec): 1592.90
CPU Time (sec): 1622.59Memory Usage (kb): 1217001
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: 1.037049e-03in global Y direction: -9.817556e+01
in global Z direction: -7.010407e-03
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: 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)
------------------------------------------------------------
Memory and Disk Usage:
Machine Type: Windows NT/x86
RAM Allocation for Solver (megabytes): 1000.0
Total Elapsed Time (seconds): 1596.35
Total CPU Time (seconds): 1623.51
Maximum Memory Usage (kilobytes): 1217001Working Directory Disk Usage (kilobytes): 2634752
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 Structure Version K-01-27:spg
Mechanica Thermal Version K-01-27:spgSummary for Design Study "optimization"
Sat Dec 10, 2005 20:29:18
------------------------------------------------------------
Run Settings
Memory allocation for block solver: 1000.0
Perform mesh smoothing after each parameter update.Remesh after each parameter update.
Parallel Processing StatusParallel 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...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: in
Force: lbfTime: sec
Temperature: F
Model Type: Three Dimensional
Points: 1762Edges: 8559
Faces: 11980
Springs: 0Masses: 0
Beams: 0
Shells: 0
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Solids: 5190
Elements: 5190
------------------------------------------------------------
Mechanica Thermal Model Summary
Principal System of Units: Inch Pound Second (IPS)
Length: in
Force: lbf
Time: secTemperature: F
Model Type: Three Dimensional
Points: 1762
Edges: 8559
Faces: 11980
Beams: 0
Shells: 0Solids: 5190
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
Status of Optimization Limits:
1. max_stress_vm 6.6134e+03 < 1.9500e+04 (satisfied)
Goal (before optimization): 6.6134e+03
Resource Check (20:44:37)
Elapsed Time (sec): 919.54
CPU Time (sec): 666.62Memory Usage (kb): 1432870
Wrk Dir Dsk Usage (kb): 233472
Begin Optimization Iteration 1 (20:44:37)
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
------------------------------------------------------------
Memory and Disk Usage:
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Machine Type: Windows NT/x86
RAM Allocation for Solver (megabytes): 1000.0
Total Elapsed Time (seconds): 1175.74
Total CPU Time (seconds): 873.30
Maximum Memory Usage (kilobytes): 1434918Working Directory Disk Usage (kilobytes): 233472
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