SYSTEM DESIGN AND SIMULATION [AM 78503]

Course objective
To integrate the knowledge of Statics, Dynamics, Strength of Materials, Mechanics of Solids, Engineering Materials and Machine Component Design into the system design of Machine, Mechanism and Structure. To be familiar the fundamentals of the system design and simulation process, and the design of some common machine and structure will be the focus.

1. Review of Matrix Algebra and Finite Element Method(1 hour)
1. Basic operations, solution methods, eigenvalues and eigen vectors
2. Nodes & elements, modelling fundamentals, computational steps and Formulation of Finite Element Equations


2. General Design Consideration(1 hour)
1. Human engineering consideration
2. Design for X methodologies


3. Introduction to Simulation Software(2 hours)
1. Definition
2. Basics of Software
3. Workbench Environment
4. Graphics and Picking
5. The Database and Files
6. Saving Files
7. File Types


4. General Analysis Procedure(1 hour)
1. Overview
2. Preliminary Decisions
3. Preprocessing
4. Solution
5. Post processing


5. Introduction to Modeling(6 hours)
1. Direct Generation
2. Creating nodes and elements
3. Filling between nodes
4. Setting Element Attributes
5. Solid Modeling
1. Using key points
2. Using lines, splines & arcs
3. Using areas and volumes (arbitrary)
4. Creating rectangle, circle, polygon, block, cylinder, prism, sphere, cone and torus
6. Concepts of hard points, line fillets and area fillets
7. Modeling with Boolean operations
1. Intersect
2. Add
3. Subtract
4. Overlap
5. Glue
6. Divide


6. Meshing(1 hour)
1. Introduction to different type of elements
2. Introduction to Meshing
3. Mapped and free meshing
4. Numbering Controls


7. Structural Analysis(6 hours)
1. Linear Static Analysis
2. Non-Linear static Analysis
3. Model and analysis of 2 D and 3 D structural elements under condition of shock, impact, initial forces, residual stress, corrosion, environment, wear, elevated temperature and low temperature


8. Fatigue and Fracture Failure(6 hours)
1. Introduction to fatigue, fatigue-life methods, stress-life and strain-life methods
2. Endurance limit and fatigue strength
3. Fluctuating stresses and fatigue failure criteria for fluctuating stresses
4. Crack propagation and energy balance
5. Model and analysis of machine element subjected to fluctuating load
6. Model and analysis of machine element subjected to fracture failure


9. Thermal Analysis(4 hours)
1. Heat flow equations, thermal stiffness matrix, thermal loads
2. Model and analysis of Steady State and Transient Thermal Analysis


10. IC Engine System Design(4 hours)
1. General design considerations, Design of Cylinder and cylinder head, Design of piston, piston ring and gudgeon pin, Design of connecting rod and crankshaft
2. Model and analysis of IC Engine System


11. Fluid Flow Problem Analysis(6 hours)
1. Fluid flow equations, fluid loads
2. Model and analysis of fluid flow problems
3. Model and analysis of turbo machine
4. Model and analysis of pressure vessel


12. Power Transmission System Analysis(6 hours)
1. Model and analysis of machine tools power transmission system


13. Design Optimization(1 hour)
1. Optimization of design problems using Simulation Software

Practical:

1. Homework Problems
1. Traditional homework problems will be assigned periodically from the textbook. These problems may include derivations and analytical problems requiring hand computations.
2. Assignments
1. 5 projects will be assigned throughout the semester requiring the use of Simulation Software. These projects are to be done individually. A brief report describing the objectives of the analysis, modelling techniques used, and results must be submitted for each project.
3. Group Design Project/Research Project
1. A group design project will also be required by the end of the semester. This project will be conceived by the group, must be of a “design” nature (no unique answer will exist), and will require the use of Simulation Software (with more than one iteration). Groups of 3-4 people will work on the project. A final report must be submitted detailing the objectives, modelling techniques and assumptions, and results of the project. In place of a design project, students are required to complete a research-oriented project that uses advanced capabilities of Simulation Software.
4. Case study
1. Industrial Engineering problems study and analysis

References:

1. M.Asghar Bhatti, “Fundamental Finite Element Analysis and Applications”, Wiley,.
2. K.L. Lawrence, “ANSYS Tutorial, ANSYS Release 11, SDC Publications.
3. Joseph E. Shigely, “Mechanical Engineering Design”, McGraw Hill Publications.
4. Alex Valance and VI Doughtie, “Design of Machine Members”, McGraw Hill Co.
5. M.F. Spott, “Machine design”, Prentice Hall India

Evaluation Schemes:
The questions will cover all the chapters of the syllabus. The evaluation scheme will be as indicated in the table below:

*There might be minor deviation in marks distribution.