Savitribai Phule Pune University, (2015 pattern)

A PROJECT STAGE-I

REPORT ON

“HEAT TRANSFER ANALYSIS OF

METAL ROD USING ANSYS &
EXPERIMENTAL VALIDATION
USING MATLAB SOFTWARE”
Submitted By:

Mr. DHAMANE PRATIK PRATAP 12

Mr. DIVE EKNATH KAKASAHEB 14

Mr. GAYAKE GAURAV GANGARAM 79

Mr. KHANDIZOD ANIKET RAHUL 102

Under the Guidance of

Prof. S.M. MAGAR

Padmashri Dr. Vithalrao VikhePatil College

of Engineering, Ahmednagar.
[2019-2020]

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CERTIFICATE
This is to certify that the following students:

1. Mr. DHAMANE PRATIK PRATAP

2. Mr. DIVE EKNATH KAKASAHEB
3. Mr. GAYAKE GAURAV GANGARAM
4. Mr. KHANDIZOD ANIKET RAHUL have
successfully completed the project stage-I work entitled “HEAT
TRANSFER ANALYSIS OF METAL ROD USING ANSYS &
EXPERIMENTAL VALIDATION USING MATLAB
SOFTWARE” under my Supervision in the partial fulfilment of
Bachelor of Engineering – Mechanical Engineering of Savitribai
Phule Pune University, during academic year 2019-20.

Date:

Place: Ahmednagar

Prof. S.M. MAGAR Dr. K.B. KALE

(Seminar Guide) (Head of Department)

Dr. U.P. NAIK

(External Examiner) (Principal)

ACKNOWLEDGEMENT

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Every orientation work has imprint of many people and this work is no different. This
work gives us an opportunity to express deep gratitude for the same. While preparing
this project report received endless help from number of people. This report would be
incomplete if we don’t convey our sincere thanks to all those who were in involved.
First and foremost, we would like to thank our respected guide Prof. S.M.
MAGAR (seminar guide) & Prof. K. B. Kale (H.O.D) for giving us an
opportunity to present this project and his indispensable support, priceless suggestions
and valuable time. Finally, we wish to thanks our friends and our families for being
supportive of us, without whom this seminar would not have seen the light of day.

Every work is an outcome of full-proof planning, continuous hard work and

organized effort. This work is a combination of all the three put together sincerely.

1) Mr. DHAMANE PRATIK PRATAP

2) Mr. DIVE EKNATH KAKASAHEB

3) Mr. GAYAKE GAURAV GANGARAM

4) Mr. KHANDIZOD ANIKET RAHUL

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INDEX

Sr No. Name of figure Page No.

1 PROFILE & HISTORY 1
2 ABSTRACT 5
3 INTRODUCTION 6

3.1 Main purpose and

application

3.2 Operating condition

and environment of the
welding machine:

3.3 Specification and

technical parameters

3.4 Structural explanation

3.5 Pneumatic and

lubrication system

3.6 Operation safety notice

4 PROBLEM STAEMENT 19
5 OBJECTIVE 19
6 FUTURE SCOPE 19
7 METHODOLOGY 20
8 LITERATURE REVIEW 21
9 REFEREACES 22

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ABSTRACT
Thermal Conductivity is an important material property in industry and
daily situations like knowing what to choose in cookware or the proper
clothing worn to leave the house. This property is described in units of
Watts per meter Kelvin and at steady state can be calculated via a
measurement of thermal resistance. Both Thermal Conductivity and
Thermal Resistance will affect the amount of heat which passes through a
system. In this experiment, a simple set-up will be employed to observe
the change in heat flow.

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CHAPTER 1

INTRODUCTION

1.1 Introduction.
The goal of this experiment is to demonstrate the effect which varying thermal
conductivities have on the heat flow through a given material. Ultimately this will
provide a better understanding of both thermal conductivity and thermal resistance

HEAT TRANSFER: - Heat transfer is a discipline of thermal engineering that

concerns the generation, use, conversion, and exchange of thermal energy between
physical systems. Heat transfer is classified into various mechanisms, such as thermal
conduction, thermal convection, thermal radiation, and transfer of energy by phase
changes. Engineers also consider the transfer of mass of differing chemical species,
either cold or hot, to achieve heat transfer. While these mechanisms have distinct
characteristics, they often occur simultaneously in the same system.

Heat conduction, also called diffusion, is the direct microscopic exchange of kinetic
energy of particles through the boundary between two systems. When an object is at a
different temperature from another body or its surroundings, heat flows so that the
body and the surroundings reach the same temperature, at which point they are
in thermal equilibrium. Such spontaneous heat transfer always occurs from a region of
high temperature to another region of lower temperature, as described in the second
law of thermodynamics.
Heat convection occurs when bulk flow of a fluid (gas or liquid) carries heat along
with the flow of matter in the fluid. The flow of fluid may be forced by external
processes, or sometimes (in gravitational fields) by buoyancy forces caused when
thermal energy expands the fluid (for example in a fire plume), thus influencing its
own transfer. The latter process is often called "natural convection". All convective
processes also move heat partly by diffusion, as well. Another form of convection is
forced convection. In this case the fluid is forced to flow by use of a pump, fan or
other mechanical means.

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Modes of Heat Transfer:

A. Conduction

B. convection

C. Radiation

Fig 1.1

MATLAB: - MATLAB (matrix laboratory) is a multi-paradigm numerical computing

environment and proprietary programming language developed by MathWorks.
MATLAB allows matrix manipulations, plotting of functions and data,
implementation of algorithms, creation of user interfaces, and interfacing with
programs written in other languages.

Although MATLAB is intended primarily for numerical computing, an optional

toolbox uses the MuPAD symbolic engine allowing access to symbolic computing
abilities. An additional package, Simulink, adds graphical multi-domain simulation
and model-based design for dynamic and embedded systems.

ANSYS: - Ansys Inc. is an American public company based in Canonsburg,

Pennsylvania. It develops and markets engineering simulation software. Ansys
software is used to design products and semiconductors, as well as to create
simulations that test a product's durability, temperature distribution, fluid movements,
and electromagnetic properties.

Ansys was founded in 1970 by John Swanson. Swanson sold his interest in the
company to venture capitalists in 1993. Ansys went public on NASDAQ in 1996. In

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the 2000s, Ansys made numerous acquisitions of other engineering design companies,
acquiring additional technology for fluid dynamics, electronics design, and other
physics analysis.

EXPERIMENTAL SETUP

AIM:- To determine the thermal conductivity of metal rod.

INTRODUCTION:-Thermal Conductivity:- It is the mode of heat transfer in which

flow of energy the sub. Takes place without any appreciable movement of an
individual moleculer.

PROCEDURE:- a) Start the electric supply.

b) Adjust the temperature in the temp. indicator by means of rotating switch for
compensating of temperature.

c) Give up to the heater by slowly rotating the dimmerstat and adjust it to voltage
equal to 80V.

d) Start the cooling water supply the jacket and adjust it about 350cc/min.

e) Go on checking the temperature at the same sufficient time (say 5min) and continue
this till satisfy steady state condition reached.

f) Note the temperature reading from 1to15.

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Fig. 1.2

SPECIFICATION:-

a) Length of the metal rod(total)=425mm

b) Size of metal rod(diameter)=25mm

c) Test length of the bar=200mm

d) No. of thermocouple mounted on bar=09

e) No. of thermocouple in the insulating shell=04

f) Heater coil (Band type)=Nichrome heater

g) Cooling coil water jacket(dia.)=90mm

h) Temperature indicator 0-200 °c with multichannel switch position 1to9

thermocouple position on metal bar position 14to15, thermocouple position to
measure rise in temp. at cooling water.

i) Dimmerstat=2A,230V

j) Voltmeter=0-100/200V

k) Ammeter=0-2A

l) Measuring flask for water flow rate at 2000cc

m) Thermal conductivity of insulation =0.22W/rad

OBSERVATION TABLE:-

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1] Measurement of temperature along the length of bar

Thermo- 01 02 03 04 05 06 07
08 09

Couple No.

 °c 84.2 75 65 60 57 55 51 49
48

2] Measurement of temperature in radial direction

Thermo- 10 11 12 13

Couple No.

 °c 44 36 29 26

3] Measurement of temperature of cooling water

Thermocouple No. 14 15

 °c 17 19

4] Measurement for mass flow rate of water

Amount of water Time required for collection Mass

flow rate in

Collected in M/C of water in (sec)

(ml/sec)

120ml 60
2

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1.2 PROBLEM STATEMENT:- It is decided to develop MATLAB code for heat

transfer analysis of metal rod & its validation is done by comparing the result with
experimental observation and ANSYS result.

1.3 OBJECTIVE:- a) To develop MATLAB code containing use of 1D,2D&3D

elements for temperature distribution in metal rod.

b) To obtain temperature distribution for metal rod in the ANSYS using 1D,2D&3D
elements.

c) To perform experimental and obtain temperature at 9 locations.

1.4 SCOPE

a) To get accurate value of the experiment.

b) Reduce Time and find errors in setup.

c) Determine thermal conductivity of different material.

d) Reduce efforts in analysis of thermal conductivity of rod.

1.5 METHODOLOGY

a) To calculate the experimental temperature values of experiment.

b) To find the values of temperature using ANSYS for various materials i.e copper,
aluminum,steel etc

c) To develop code on MATLAB using experiment equations.

d) To find temperature values using developed MATLAB code.

e) To compare all values (Experimental, ANSYS, MATLAB).

1.6 Organization of Dissertation

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It was observed while doing thermal practicals that the calculations of experiment are
very lengthy. As no. of thermocouple were used in machine it becomes difficult to find
the values or the variation in temperature values. Post processing is very difficult in
manual experimentation, hence to reduce the post processing time and make it simple,
there is a need of advanced technology.

Hence it was decided to make use of MATLAB software for finding or for comparing
the reults. By developing a MATLAB program it becomes easy to calculate or find
values.

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CHAPTER 2

LITERATURE REVIEW

 Wei Li , Cher Ming Tan.( 28 August 2007) - Enhanced finite element

modelling of Cu electromigration using ANSYS and matlab.
 Fangqin Yang, Yangfu Jin*, Xin Qian (2013-01-11) - Study on Thermal
Conductivity of Metal/Polymer Composites Based on Software ANSYS.
 Eyad Raafat, Ahmed Nassef , Medhat El-hadek , Abla El-Megharbel ,*( 13
October 2019) - Fatigue and thermal stress analysis of submerged steel pipes
using ANSYS software.
 Obula Reddy Kummithaa *, B.V.R. Reddy (2016) - Thermal Analysis of
cylinder block with fins for different materials using ANSYS.

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CHAPTER 3

SIMULATION WORK:-

Fig. 3.1 copper

Fig. 3.2 Aluminium

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Fig. 3.3 Brass

Fig. 3.4 Cast Iron

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CHAPTER 4
Experimental validation:-
Comparison between Ansys and practical values graph.

Chart Title
90
80
70
60
Temprature

50
40
30
20
10
0
T1 T2 T3 T4 T5 T6 T7 T8 T9
Distance from heating source

Practical values ANSYS values

Fig. 4.1

Effect on end point temperature by changing material.

48.16
End point temperature

40.73 44.16
32.42 30.13 28.14
23.5

pe
r m a ss el ro
n el ld
p iu Br ste i Ste Go
Co in ss
t l
um le C as ra
Al i n c tu
a ru
St St
Materials’

Fig. 4.2

REFERENCES: -

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1. G. Babu, M. Lavakumar,Heat Transfer Analysis and Optimization of

Engine Cylinder Fins of Varying Geometry and Material, Journal of
Mechanical and Civil Engineering (IOSR-JMCE, Volume 7, Issue 4
(Jul. - Aug. 2013), PP 24-29

2. ] Biermann E. and Pinkel B., Heat Transfer from Finned Metal

Cylinders in an Air Stream, NACA Report No. 488 (1935).

3. X W Zhao，L Ye.: Journal of Applied Polymer Science, 2009, Vol.

111(2): p. 759-767.

4. W Y Zhou, S H Qi, P Wu, et al.: Engineering Plastics Application,

2004, Vol. 32(12): p. 62-65. In Chinese.

5. Dalleau D, Weide-Zaage K. Microelectron Reliab 2001;41:1625

6. ] Lloyd JR, Clements J, Snede R. Microelectron Reliab 1999;39:1595.

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