SolidWorks Simulations

These simulation projects show how I have learnt CFD and FEA, and how to use it to guide engineering designs. Below are 4 key projects which highlight my learning and skills regarding these analysis tools.

Pressure & Velocity Gradients

Created a virtual wind tunnel to simulate the performance of a carbon fiber spoiler design. Based off of the image displayed to the left, we can see it creates a peak pressure drop of roughly 1000 Pa over the surface of the spoiler. Using the Global Goal feature, we found that at 100 km/h, this spoiler creates a down force of 143 N.

Using surface goals, it was found that there was an average pressure drop of 660 Pa on the spoiler. Further simulation can find the greater impact this has by creating a rough model of an exterior car body.

Car Radiator Heat Simulation

Created a functional radiator through 3D sketch and linear pattern allowing me to create winding tube and radiator fins effectively. Used the flow simulation feature on SolidWorks to simulate the flow of water to see the heat transfer capabilities of this setup.

Findings: The temperature of the fluid inside the tubing decreased by roughly 25° C while the temperature of the outside material stayed below 90° C.

Further Testing: Changing the material used from 2024 Aluminum which is favored for its strength to 6063 could show further cooling properties. Changing the widths and amount of fins could show differing results.

Using different software could allow the visualization of the surrounding air as well and incorporate the flow of air through the fins like a real car.

The cutout on the bottom edge also served to reduce concentrated stress and to reduce material usage. The change in cutout geometry and additional cut included in the gusset portion of the part reduced weight by 14.4%.

Drone Arm Stress Test

The design of Drone Arm V3 was inspired by several drone designs found on in the internet. In this design, I experimented using vertical cuts to reduce material usage. In the first iteration (Shown to the right), stress was concentrated on edges closer to the mounting side.

To counteract this behavior in other iterations, I changed the cutout geometry, by increasing spacing closer to the mounting side, and decreasing material usage near the end. This change in geometry helped distribute stress uniformly over the body, discouraging premature failure when subjected to the same loads.

Initial FEA Testing

This simple bracket Design served as my initial test point to learn more about FEA and how to use it properly. Using this tool I was able to find that the bracket was well below it's yield strength using the Von Mises Criterion.

The simulation and analysis also allowed me to clearly visualize where there is stress concentrations in the bracket. Looking at the green sections, we can see that they are mostly present where the arms connect to the screw holes, this is due to the change in area, and could be mitigated by including fillets in the design.

Fan Flow Simulation

Used Lofted surfaces and circular pattern to create fan blades around a center rotating structure. Then analyzed and used flow simulation to understand air flow inside behaves at an angular frequency of 200 rad/s.

I discovered that at this rotating speed, with 3 fan blades of 50mm around a center structure of 50mm produces a max speed of 5 m/s.