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This report presents the findings of a project conducted as part of the Rapid Manufacturing Technologies course during the Bachelor's program. The project focused on flow analysis and enhancing the rapid manufacturability of a vortex generator. Rapid prototyping techniques were employed to create scale models based on three-dimensional computer-aided design (CAD) data. Vortex generators (VG) are aerodynamic devices typically attached to lifting surfaces or rotor blades of wind turbines.
The primary objective of this project was to increase the complexity of the existing vortex generator, with a focus on rapid manufacturability.
The analysis aimed to provide improved results, and the design had to be suitable for mass production.
SolidWorks, developed by Dassault Systems, is a computer-aided design and engineering software primarily used for solid modeling. SolidWorks offers a user-friendly interface and is known for its efficiency in modeling complex objects. In this project, SolidWorks was chosen due to its compatibility with ANSYS for subsequent analysis.
ANSYS is a widely-used design software for analyzing product durability and various properties, including fluid flow and velocity gradient.
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It offers features like Finite Element Analysis (FEA) to test and simulate a product's stability. While ANSYS was not used extensively in this course, it is known for its robust simulation capabilities.
The project's initial phase involved designing the vortex generator using SolidWorks. Subsequently, flow and velocity analysis was performed using ANSYS. The design was evaluated for feasibility in usage, production, and rapid manufacturability.
The vortex generator was designed in SolidWorks with chamfers incorporated into its surface.
Figures below depict the front view, top view, and side view of the part, showcasing its layered structure.
Flow and velocity analysis were conducted on the vortex generator to assess its strength and stability. Pressure pathways were determined based on the part's location and orientation within the vehicle. The analysis indicated improved aerodynamic stability compared to the previous design.
| Location | Velocity (m/s) |
|---|---|
| Front End | 12.5 |
| Rear End | 10.2 |
| Parameter | Value |
|---|---|
| Flow Type | Laminar |
| Stability | Improved |
A comparison between the regular vortex generator and the modified vortex generator is presented in the Table below. The analysis showed that the modified vortex generator exhibited laminar flow, enhancing the aerodynamic stability of the vehicle.
| Generator Type | Flow Type | Aerodynamic Stability |
|---|---|---|
| Regular Vortex Generator | Turbulent | Lower |
| Modified Vortex Generator | Laminar | Improved |
This project provided an opportunity to explore the capabilities of both SolidWorks and ANSYS, particularly in conducting velocity and flow analysis. Advantages of using both software tools include prior familiarity and compatibility between them. However, limitations were observed, such as SolidWorks' limited capacity for certain types of analysis and the time-consuming nature of ANSYS simulations.
Throughout the course MG2128 - CAD and Other Tools in Industrial Processes, various CAD tools like GibbsCAM and SolidEdge were introduced, enhancing my skills for future industrial work. Additionally, I gained insights into the challenges of software compatibility and the complexities arising when transferring features between different software programs.
This course has broadened my perspective and motivated me to contribute to addressing software compatibility issues in engineering practices.
Flow Analysis and Rapid Manufacturability of Vortex Generator. (2024, Jan 05). Retrieved from https://studymoose.com/document/flow-analysis-and-rapid-manufacturability-of-vortex-generator
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