1.1 Background: Fabrication and Analysis of Double Glazing Windows Using Ansys

Fabrication and Analysis Of Double Glazing Windows Using Ansys
CHAPTER 1
INTRODUCTION
It provides the background and research issue in order to make a clear landscape
and explain what will go on with the project.
1.1 Background
Indoor climate involves many elements, these elements will influence the inside occupants
feeling about the temperature, humidity and air quality .etc. There are too much details
related to the sensitivity of occupants, which can be described as a standard concept, the
thermal comfort. Thermal comfort defined as “the condition of human mind in which
satisfaction is expressed with the thermal environment”. Because it is a scale that based on
the occupants subjective feeling, therefore the sample must be a certain amount of a group
of persons. In 1962, Macpherson defined the following six factors that affecting thermal
sensation: four physical variables which are air temperature, air velocity, relative humidity,
mean radiant temperature, and two personal variables which are clothing insulation and
activity level .It is obviously can be notice that the indoor temperature is a really essential
element of indoor climate. Indoor temperature is not only related to the feeling of indoor
staff, but also has something to do with their working efficiency. Forget about the all the
science issue, the temperature in the house is always discussed in public daily life,
especially for wintertime. Keeping an acceptable indoor temperature related to supply heat
and reduce heat loss. There is no tight building. Therefore, the energy leakage can be found
everywhere. Joint between different building constructions is a tricky part. The air leakage
will take away the heat. Although this part is a hard to solve, it did not occupy too many
percent of the total heat loss. Focusing on the windows, the window is used as a media of
outside vision; also, it will make the building looks beautiful. Unfortunately, heat loss from
windows aspect occupied 40% of total loss.
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Department Of Mechanical Engineering, MCET
1.2 Purpose
The aim of this project is to find reasonable ways to defend the heat loss from windows,
and the focal point is on the structure of the whole window. Firstly, the process focusing
on the glass section, find a low U-value glazing construction. Secondly, focusing on the
frame structure, explore the new method of construct the window frame.
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CHAPTER 2
INTRODUCTION TO CAE
Computer-aided engineering (CAE) is the broad usage of computer software to aid in

engineering analysis tasks. It includes finite element analysis (FEA), computationalfluid
dynamics (CFD), multibody dynamics (MBD), durability and optimization.
Software are used to analyze CAD geometry tools that have been developed to support
these activities are considered CAE tools. CAE tools are being used, for example, to
analyze the robustness and performance of components and assemblies. The term
encompasses simulation, validation, and optimization of products and manufacturing tools.
In the future, CAE systems will be major providers of information to help support design
teams in decision making. Computer-aided engineering is used in many fields such as
automotive, aviation, space, and shipbuilding industries.
In regard to information networks, CAE systems are individually considered a single node
on a total information network and each node may interact with other nodes on the
network.
CAE systems can provide support to businesses. This is achieved by the use of reference
architectures and their ability to place information views on the business process. Reference
architecture is the basis from which information model, especially product and
manufacturing models.
The term CAE has also been used by some in the past to describe the use of computer
technology within engineering in a broader sense than just engineering analysis. It was in
this context that the term was coined by Jason Lemon, founder of SDRC in the late 1970s.
This definition is however better known today by the terms CAxand PLM.
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2.1 CAE FIELDS AND PHASES
CAE areas covered include:
 Stress analysis on components and assemblies using Finite Element Analysis (FEA)
 Thermal and fluid flow analysis Computational fluid dynamics (CFD);
 Multibody dynamics (MBD) and Kinematics;
 Analysis tools for process simulation for operations such as casting, molding, and
die press forming.
 Optimization of the product or process.
In general, there are three phases in any computer-aided engineering task:
 Pre-processing – defining the model and environmental factors to be applied to it.

(typically a finite element model, but facet, voxel and thin sheet methods are also
used)
 Analysis solver (usually performed on high powered computers)
 Post-processing of results (using visualization tools)
This cycle is iterated, often many times, either manually or with the use of
commercialoptimization software.
2.2 BENEFITS OF CAE
 Since simulating reality is less time consuming, CAE processes save on time and
money
 CAE reduces the errors in design and drawing process
 The impacts of changing parameters on a system can be studied with more accuracy
 Robustness and performance of components and assemblies can be analyzed. 
 CAE allows for easy visualization and improves designs.
 CAE aids ease of manufacturing.
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CHAPTER 3
INTRODUCTION TO ANSYS WORKBENCH
ANSYS Workbench Mechanical can link a thermal analysis to a structural analysis,

sharing Engineering Data, Geometry and Model directly. When directly linked, bodies in
the structural model cannot be suppressed independently of the thermal analysis and
meshing and contacts cannot be set differently. 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 the 2000s, Ansys made numerous acquisitions of
other engineering design companies, acquiring additional technology for fluid dynamics,
electronics design, and other physics analysis.
Ansys develops and markets finite element analysis software used to simulate
engineering problems. The software creates simulated computer models of structures,
electronics, or machine components to simulate strength, toughness, elasticity, temperature
distribution, electromagnetism, fluid flow, and other attributes. Ansys is used to determine
how a product will function with different specifications, without building test products or
conducting crash tests.For example, Ansys software may simulate how a bridge will hold
up after years of traffic, how to best process salmon in a cannery to reduce waste, or how to
design a slide that uses less material without sacrificing safety.
Most Ansys simulations are performed using the Ansys Workbench software, which
is one of the company's main products. TypicallyAnsys users break down larger structures
into small components that are each modeled and tested individually. A user may start by
defining the dimensions of an object, and then adding weight, pressure, temperature and
other physical properties.Finally, the Ansys software simulates and analyzes movement,
fatigue, fractures, fluid flow, temperature distribution, electromagnetic efficiency and other
effects over time.
Ansys also develops software for data management and backup, academic research
and teaching. Ansys software is sold on an annual subscription basis.
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3.1 System Requirements:
The following description shows the minimum and recommended

HardwareandSoftware requirements:
Minimum:
 Windows 7, 8, 10, Server 2008, Server 2012, 64 bits (PC or Mac computers using
Boot Camp).
 Any CPU (Intel i5/ i7/ Xeon recommended).
 Any GPU that is compatible with OpenGL 3.2. (integrated graphic cards Intel HD
4000 or above).
 Small projects (under 100 images at 14 MP): 4 GB RAM, 10 GB HDD Free Space.
 Medium projects (between 100 and 500 images at 14 MP): 8 GB RAM, 20 GB
HDD Free Space.
 Large projects (between 500 and 2000 images at 14 MP): 16 GB RAM, 40 GB
HDD Free Space.
 Very Large projects (over 2000 images at 14 MP): 16 GB RAM, 80 GB HDD Free
Space.
Recommended:
 Windows 8, 10 64 bits.
 CPU quad-core or hexa-core Intel i7/Xeon.
 GeForce GPU compatible with OpenGL 3.2 and 2 GB RAM. 
 Hard disk: SSD.
 Small projects (under 100 images at 14 MP): 8 GB RAM, 15 GB SSD Free Space.
 Medium projects (between 100 and 500 images at 14 MP): 16GB RAM, 30 GB
SSD Free Space.
 Large projects (over 500 images at 14 MP): 32 GB RAM, 60 GB SSD Free Space. 
 Very Large projects (over 2000 images at 14 MP): 64 GB RAM, 120 GB SSD Free
Space.
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CHAPTER 4
LITERATURE REVIEW
EXPERIMENTAL VALIDATION OF A BOUNDARY LAYER CONVECTIVE HEAT

FLUX MEASUREMENT TECHNIQUE, K. S. KULKARNI, U. MADANAN, T. W.
SIMON AND R. J. GOLDSTEIN: In this journal Steady thermal boundary layer is
sufficiently thick, wall heat fluxes and associated convective heat transfer coefficients can
be directly calculated from measured temperature distributions taken within it using a
traversing thermocouple probe. The boundary layer can be laminar, turbulent, or
transitional and on a surface of arbitrary surface temperature distribution and geometry.
Herein, this technique is presented and validated in a steady, turbulent, two-dimensional
boundary layer on a flat, uniform-heat-flux wall. Care is taken to properly account for
radiation from the wall and conduction within the thermocouple wire. In the same setting,
heat flux measurements are made for verification purposes using an energy balance on a
segment of the test wall carefully designed to minimize and include radiation and
conduction effects. Heat flux values measured by the boundary layer measurement
technique and by the energy balance measurement agree to within 4.4% and the difference
between the two lie completely within their respective measurement uncertainties of 5.74%
and 0.6%.
OPTIMIZATION OF THERMAL CONDUCTIVITIES OF ISOTROPIC AND

ORTHOTROPIC SOLIDS, R. A. MERIC: In it Optimization of thermal conductivities of
isotropic and orthotropic solids is treated as a steady-state optimal control problem.
Nonlinear necessary optimum conditions are first derived for the so-called material
optimization problem, and a general numerical method of solution is then proposed. The
iterative numerical procedure solves the linearized state and co-state equations by the finite
element method and minimizes the performance index by the conjugate gradient method.
Numerical solutions, checked with exact results when possible, are given for an isotropic
infinite plate and a cylinder.
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HEAT TRANSFER STUDY IN A LINEAR TURBINE CASCADE USING A THERMAL

BOUNDARY LAYER MEASUREMENT TECHNIQUE, S. HANAND R. J.
GOLDSTEIN: In which an experimental system is designed, constructed, and operated
to make local measurements of heat transfer from constant-temperature surfaces in a linear
turbine cascade. The system includes a number of embedded heaters and a control system
to maintain the turbine blades and end walls in the cascade at a uniform temperature. A
five-axis measurement system is used to determine temperature profiles normal to the
pressure and suction sides of the blades and to the end wall. Extrapolating these
measurements close to the surface, the local heat transfer is calculated using Fourier's law.
The system has been tested in the laboratory, and results are shown for the temperature
distributions above the surfaces and for the local variations in the Nusselt number on the
different surfaces in the cascade. The system can also be used to study the heat and mass
transfer analogy as considerable data are available for mass transfer results with similar
geometries.
OPTIMUM HEATING OF PRESSURE COMPONENTS OF STEAM BOILERS WITH

REGARD TO THERMAL STRESSES, PIOTR DZIERWA: It describes a method for
determining time–optimum fluid temperature changes is presented. In contrast to current
standards, stepwise fluid temperature changes are allowed. The optimum fluid temperature
changes are assumed in the form of a simple time function. It is possible to increase the
fluid temperature stepwise, and then the fluid temperature can be increased with a constant
rate at the beginning of the heating process. The permissible rates of the fluid temperature
change determined by the proposed method are smaller than those obtained by boiler
standards. But, due to the abrupt increase in fluid temperature, the heating time of a thick-
walled component is of the same order as in the case of calculations according to EN
12952-3 European Standard. However, the total circumferential stresses on the edge of the
hole do not exceed the allowable value.
HEAT TRANSFER AND EVAPORATION RATES OF SMALL LIQUID DROPLETS

ON HEATED HORIZONTAL SURFACES, ELYSSA F. CRAFTON AND W.Z. BLACK:
The journal explains the evaporation rates of small liquid droplets were observed and
quantified in order to measure heat transfer rates when individual droplets evaporate on a
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horizontal heated surface. Single water droplets with a post-impact diameter of

approximately 1 mm and n-heptane droplets approximately 5 mm in diameter were gently
placed on aluminum and copper surfaces that were maintained at temperatures below the
saturation temperatures of the liquids, and the evaporation was observed at atmospheric
pressure. The droplets were videotaped throughout the entire evaporation process and
transient variations of the diameter, height were measured. From the measured quantities,
the contact angle and evaporation rates were calculated and used to predict the heat transfer
rate on the surface. The results show that the trends in the wetted diameter, height and
contact angle for water droplets are fundamentally different than the geometric changes for
heptane droplets. Even though the evaporation rates of the n-heptane droplets were an order
of magnitude greater than the water droplets, the heat fluxes for the n-heptane droplets are
approximately an order of magnitude less than the water drops. The experimental results
are compared with recent analytical models which predict the evaporation rates of small
liquid droplets.
MULTI-REGION HEAT CONDUCTION PROBLEMS BY BOUNDARY ELEMENT

METHOD (M.AKIF ATALAY, E.DILARAAYDINAND MURATAYDIN): This paper is
concerned with boundary element solution of two dimensional steady-state heat conduction
problems in multi-regions. In the proposed method, each region with different heat transfer
properties is considered as a piecewise homogeneous in a heterogeneous system. The
solution scheme akin to a finite difference method or finite element method sweeping
treatment is adopted. The generated integral equation for a typical region is swept to obtain
the system matrix for all regions in a single step without considering compatibility
conditions explicitly at interfaces. In the case of linear or higher order elements, the non-
square global system matrix is solved by the singular value decomposition method. Multi-
region test problems for square and circular domains are considered and numerical results
are presented.
A NUMERICAL STUDY OF BOUNDARY-LAYER HEAT AND MASS TRANSFER IN

A FORCED FLOW OF HUMID AIR WITH SURFACE STEAM CONDENSATION,
E.P.VOLCHKOV, V.V.TEREKHOV, V.I.TEREKHOV: In which data obtained by
numerical solution of boundary-layer flow, energy and diffusion equations for laminar and
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turbulent flows of humid air are described. The effect of vapour concentration and vapour–
gas mixture temperature on the intensity of and similarity between the heat- and mass-
transfer processes in the presence of surface vapour condensation is considered. It is shown
that the Reynolds analogy is valid in the range of mass vapour concentration in the flow
core C10<0.2. In the region of higher vapour concentrations (condensation of a vapour with
incondensable species), the analogy between the transfer phenomena is violated and the
assumption that Le=1 can no longer be used.
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CHAPTER 5
METHODOLOGY
5.1 BASICS OF STEADY STATE HEAT TRANSFER
 For a steady-state (static) thermal analysis in Simulation, the temperatures {T} are
solved for in the matrix below:
K T T   QT 
 Assumptions:
o No transient effects are considered in a steady-state analysis
o [K] can be constant or a function of temperature
o {Q} can be constant or a function of temperature
 Fourier’s Law provides the basis of the previous equation:
o Heat flow within a solid (Fourier’s Law) is the basis of [K]
o Heat flux, heat flow rate, and convection are treated as boundary conditions
on the system {Q}
o Convection is treated as a boundary condition although temperature-
dependent film coefficients are possible
 It is important to remember these assumptions related to performing thermal
analyses in Simulation.
5.2 GEOMETRY
• In thermal analyses, all types of bodies supported by Simulation may be used.

o Solid, surface, and line bodies are supported.
o For surface bodies, thickness must be input in the Details view of the
Geometry branch.
o Line bodiescross-section and orientation is defined within Design Modeler.
o Cross-section and orientation information results in an ‘effective’ thermal
cross-section.
o Only temperature results are available for line bodies.
o The “Point Mass” feature is not available in thermal analyses.
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 Shell and line body assumptions:

o For shell bodies through-thickness temperature gradients are not available.
Shells assume temperatures on top and bottom of surface are the same.
o For line bodies through thickness variation in the temperature is not
available. Line bodies assume the temperature is constant across the cross-
section.
o Temperature variation will still be considered alongthe line body.
5.3 MATERIAL PROPERTY
The only required material property is thermal conductivity
 ThermalConductivity is input in the Engineering Data application.
Temperature-dependent thermal conductivity is input as a table.
Fig 5.1 Material Property
If any temperature-dependent material properties exist, this will result in a nonlinear

solution.
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5.4 ASSEMBLIES – SOLID BODY CONTACTS
 When importing assemblies of solid parts, contact regions are automatically created
between the solid bodies enabling heat transfer between parts in an assembly.
 No heat spreading is considered in the contact/target interface.
– Heat flow within the contact region is in the contact normal direction only.
– Heat flows only if a target element is present in the normal direction of a
contact element.
Fig 5.2 Solid Body Contacts
In the figure on the left, the solid green double-arrows indicate heat flow within the contact
region. Heat flow only occurs if a target surface is normal to a contact surface.The light,
dotted green arrows indicate that no heat transfer will occur between parts.
If the parts are initially in contact, heat transfer will occur between the parts.If the parts are
initially out of contact no heat transfer takes place.
Summary:
Heat Transfer Between Parts in Contact Region?

Contact Type
Initially Touching Inside Pinball Region Outside Pinball Region
Bonded Yes Yes No
No Separation Yes Yes No
Rough Yes No No
Frictionless Yes No No
Table 5.1 Heat Transfer Between Parts In Contact Region

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The pinball region determines when contact occurs and is automatically defined and set to a
relatively small value to accommodate small gaps in the model.
The amount of heat flow between two parts is defined by the contact heat flux q:
– q  TCC  Ttarget  Tcontact 
whereTcontact is the temperature of a contact “node” and Ttarget is the temperature of the
corresponding target “node”.
Perfect thermal contact conductance between parts means that no temperature drop is
assumed at the interface. One may want to include finite thermal conductance instead.
The contact conductance can be influenced by many factors:

 surface flatness
 surface finish
 oxides
 entrapped fluids
 contact pressure
 surface temperature
 use of conductive grease
In ANSYS Professional licenses and above, the user may define a finite thermal contact
conductance (TCC) if the Pure Penalty or Augmented Lagrange Formulation is used.
The thermal contact conductance per unit area is input for each contact region in the Details
view.
If thermal contact resistance is known invert this value and divide by the contacting area to
obtain TCC value.
Thermal Contact Notes:
 For symmetric contact the user does not need to account for a ‘double’ thermal
contact resistance.
 MPC bonded contact allows for perfect thermal contact conductance.
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5.5 HEAT LOADS
HEAT FLOW:
 A heat flow rate can be applied to a vertex, edge, or surface. The load gets
distributed for multiple selections.
 Heat flow has units of energy/time.
HEAT FLUX:
 A heat flux can be applied to surfaces only.
 Heat flux has units of energy/time/area.
INTERNAL HEAT GENERATION:
 An internal heat generation rate can be applied to bodies only.
 Heat generation has units of energy/time/volume.
A positive value for heat load will add energy to the system.
 Perfectly Insulated:
– Perfectly insulated condition is applied to surfaces.
– This is the default condition in thermal analyses when no load is applied.
– This load type is used as a way to remove loading on specified surfaces.
– For example, it may be easier for a user to apply heat flux or convection on
an entire part, then use the perfectly insulated condition to selectively
‘remove’ the loading on some surfaces.
Fig 5.3 Heat Load
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5.6 THERMAL BOUNDARY CONDITIONS
TEMPERATURE, CONVECTION AND RADIATION:

 At least one type of thermal boundary condition must be present to prevent the
thermal equivalent of rigid body motion.
 Given Temperature or Convection load should not be applied on surfaces that
already have another heat load or thermal boundary condition applied to it.
 Perfect insulation will override thermal boundary conditions.
GIVEN TEMPERATURE:
 Imposes a temperature on vertices, edges, surfaces or bodies.
 Temperature is the degree of freedom.
CONVECTION:
 Applied to surfaces only (edges in 2D analyses).
 Convection q is related to a film coefficient h, the surface area A, and the difference
in the surface temperature Tsurface& ambient temperature Tbulk.
q  hATsurface  Tambient 
“h” and “Tbulk” are user-input values.

The film coefficient h can be constant or temperature dependent.
5.7 TEMPERATURE-DEPENDENT CONVECTION:
 Select “New Convection…” for the Correlation.
 The “Engineering Data” tab will open and the Coefficient Type can then be defined
for the convection load.
 Determine what temperature is used for h(T):
– Average film temperature, T=(Tsurface+Tbulk)/2
– Surface temperature, T= Tsurface
– Bulk temperature, T= Tbulk
– Difference of surface and bulk temperatures

T=(Tsurface-Tbulk)
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Fig 5.4 Temperature Dependance
Fig 5.5 Convection
Select the temperature-dependency from the pull-down menu

The convection data can also be imported from a file.
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Fig 5.6 Details Of Convection
Fig 5.7 Radiation Details
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5.8 RADIATION:
 Applied to surfaces (edges in 2D analyses)
4

QR  FA Tsurface  Tambient
4

Where:
σ = Stefan-Boltzman constant
ε = Emissivity
A = Area of radiating surface
F = Form factor (1)
 Provides for radiation to ambient only (not between surfaces)

 Form factor assumed to be 1
 Stefan Boltzman constant is determined and set automatically based on the active
working unit system
5.9SOLUTION OPTIONS
• Solution options are set under the “Solutions” branch:

o The ANSYS database can be saved
o Two solvers are available in Simulation:
o Default = Program Chosen
o Iterative = PCG solver
o Direct = sparse solver
o The “Weak Springs” and “Large Deflection”
options are meant for structural analyses only,
so they can be ignored for a thermal analysis
Informative settings show the user the status of the analysis:
 “Analysis Type”
 Nonlinear solution
 Solver working directory
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 Any solver messages which appear after solution can be checked afterwards
under “Solver Messages”
Fig 5.8 Outline
To solve the model, request results and “Solve”
• If a “Solution Information” branch is requested, the details of the solution output

can be examined
• To perform a thermal-stress solution add structural supports and/or loads and
request structural results, then solve the model
• The following will be performed automatically:
• A steady-state thermal analysis will be performed
• The temperature field will be mapped back onto the structural model
• A structural analysis will be performed
– Simulation automates this type of coupled-field solution
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Fig 5.9 Solution
5.10 RESULTS AND POSTPROCESSING
Various results are available for postprocessing:
 Temperature
 Heat Flux
 “Reaction” Heat Flow Rate
In Simulation, results are usually requestedbefore solving, but they can be requested
afterwards, too.
A new solution is not required for retrieving output of a solved model.
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CHAPTER 6
MODEL AND DESIGN FOR ANSYS ANALYSIS
6.1 WOODEN FRAME WITH SINGLE GLASS
Fig 6.1 Wooden Frame with Single Glass
The fig shows single layer glass with wooden frame. The heat from the sun reaches the
outer sides of the window through radiation process .From there by conduction heat enter
to the room by passing the single layer glassing and wooden frame. To simplify, the main
part heat transfer can be calculated by the equation: Q=UA –ka* dt/dx.Many types of
materials are used to construct the window frame. The most popular materials are timber,
polymer and metal (Aizan, et al.2008).
There is amounts kind of frame material with the U-value:
FRAME MATERIAL U VALUE

Cypress 0.097 W/m2K
Balsa 0.055 W/m2K
Fir 0.11 W/m2K
Maple or Oak 0.166 W/m2K
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Aluminum alloy (Al-Mg-Si) 0.09 W/m2K
PVC (polyvinylchloride) 0.09 W/m2K
Yellow Pine 0.147 W/m2K
Table 6.1 U Value For Different Materials
To date, the polymer plays an important part in energy saving design of window frame. As
shown above, it got a relative low U-value when compare with some timber. It also gets
both light and high strength property that better than some low heat transfer rate timber,
because some of them get worse strength. Still the aluminum alloy frame can be found
everywhere in some old house in country like India. Both of the window and door frame of
some new house even constructed by the aluminum alloy. From the value indicates, this
kind of window do bad in energy saving. To some degree, they just got the property of
beauty and safe.
6.2 DOUBLE GLAZING WINDOW
Fig 6.2 Double Glazing Window
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For some developing country, such as India, large amounts of building window or single
house window are still the one glazing window. The different between this two is the inside
gap contains or not, it could be filling with air by increase of glazing layer, the U-value is
decrease. It has nothing to do with what kind of frame it would be, and it has no related to
what kind of assignments is done within the gap of layers.
From the table given it is observed that the polymer plays an important part in energy
saving design of window frame. As shown above, it got a relative low U-value when
compare with some timber. It also gets both light and high strength property that better than
some low heat transfer rate timber, because some of them get worse strength.
6.3 DESIGNS FOR THE MODEL
Single glass
Glass dimension 10*10 inch
Glass thickness 3mm
Double glass
Glass dimension 10*10 inch
Glass thickness 3mm
Air gap distance between glasses 3mm
Bounding Box
Length X 2.6e-002 m
Length Y 0.15 m
Length Z 0.15 m
Length Z1 (single glass)
Table 6.2 Design Model
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CHAPTER 7
MESHING
7.1 ANSYS MESHING
ANSYS Meshing is a general-purpose, intelligent, automated high-performance product. It
produces the most appropriate mesh for accurate, efficient multiphysics solutions. A mesh
well suited for a specific analysis can be generated with a single mouse click for all parts in
a model.
7.2 MESH INDEPENDENT STUDY
Mesh or Grid independent solution is a solution that does not vary significantly even when
you refine your mesh further.When you start with a coarse mesh and solve, you may notice
difference in results as you make your mesh finer. But, there exists a limit, beyond which
you won't observe any changes in the results even after you make it finer. Then we may
state that we have achieved grid independence. At this point, the mesh will be fine enough
to capture the most intricate details of the flow, which is why making it finer will not make
any changes in the results.
7.3 MESH: HEXA DOMINANT (FINE, DOUBLE GLAZING PVC FRAME
WINDOW
Fig 7.1 Double Glazing Window Meshing

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When you start with a coarse mesh and solve, you may notice difference in results as you make
your mesh finer. But, there exists a limit, beyond which you won't observe any changes in the
results even after you make it finer. Then we may state that we have achieved grid independence.
At this point, the mesh will be fine enough to capture the most intricate details of the flow, which
is why making it finer will not make any changes in the results.
7.4 SINLE GLASS WOODEN FRAME WINDOW MESH
Fig 7.2 Single Glass Wooden Frame Window Mesh
A program controlled triangle surface mesh is applied on single glazing

window, when you start with a coarse mesh and solve, you may notice difference in results as
you make your mesh finer. But, there exists a limit, beyond which you won't observe any
changes in the results even after you make it finer. Then we may state that we have achieved grid
independence. At this point, the mesh will be fine enough to capture the most intricate details of
the flow, which is why making it finer will not make any changes in the results.
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CHAPTER 8
RESULTS AND DISCUSSIONS

8.1 SINGLE GLASS WOODEN FRAME WINDOW
Fig 8.1 Result 1
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8.2 DOUBLE GLAZING PVC FRAME WINDOW
Fig 8.2 Result 2
It is very clear from the result of analysis done over wooden frame single glass window and
double-glazing PVC frame window. The rate of heat transfer in double-glazing PVC frame
is lesser than other one. A difference of .5W/M2 is obtained from the analysis result, hence
our assumption was correct and it is sure that there exists a mush high insulation capacity
for the double glazing pvc frame window. In order for experimental evaluation and further
study, this result of analysis can be used as the base.
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CHAPTER 9
FABRICATION
Material used for fabrication,
 PVC frame
 Glass
 Rubber gasket
 Silicon Glue
 Duct Tape
PVC FRAME: The polymer plays an important part in energy saving design ofwindow
frame. It got a relative low U-value when compare with some timber. It also gets both light
and high strength property that better than some low heat transfer rate timber, because
some of them get worse strength.
Air Gap
PVC frame
Fig 9.1 The Cross-Section Of Frame
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The cross-section of Frame: The brown areas show the PVC skeleton of the frame, and the
light green areas show air cavities. The blue areas show the supporting steel and the
continuous parts of the hardware used for opening the frame.
GLASS: Here we use two parallel glasses and we fill air between the space. Instead ofair
we can fill gas with good thermal property between each glazing and gets a reduction of
heat loss. The most common material is absorbing gas, the rest are silica aerogel,
chromogenic materials and phase change materials (PCM)
Usually, the gas filled window can be fill with lots kind of gas, these gas sometime are
noble gas or some simple gas such as the carbon dioxide. For safety and valid, the filled
gas must be non-toxic, low conductivity and get high viscosity.
glasses
Radiation through glassing Air gap
PVC frame
Conduction through the glassing spacer bars
Air leakage around opening light & frame
Conduction through the frame
Fig 9.2 Heat Loss and Heat Gain
RUBBER GASKET: A gasket is a mechanical seal which fills the space between twoor
more mating surfaces. Generally to prevent leakage from or in to the joined objects while
under compression. Gaskets allows for less than perfect mating surfaces on machine parts
30
where they can fill irregularities. Gaskets are commonly produces by cutting from sheet
material. I is usually desirable that the gasket be made from a material that is to some
degree yielding. Such that it is able to deform and tightly filled space it is designed for
including any slight irregularities. A few gaskets required to an application of sealant
directly to the gaskets surface to function properly.
Fig 9.3 Rubber Gasket
SILICON GLUE: Silicone glue is a type of adhesive that contains silicon and
oxygenatoms, making it a good water-resistant solution. It is used in many areas because of
its stability, both chemically and thermally. Silicone glue is also resistant to weathering and
moisture, unlike many other adhesives. Silicones also known as polysiloxanes are polymers
that include any inert, synthetic compound made up of repeating units of siloxane which is
a chain of alternating silicon atoms and oxygen atoms, frequently combined carbon or
hydrogen or both. They are typically heat resistant and rubber like and are used in sealants,
adhesives, lubricants, thermal and electrical insulations etc.
Fig 9.4 Silicon Glue
31
Some common forms including silicone oil, silicone grease, silicone rubber, silicone resin
and silicone chock. Silicones are of three types
 Straight chain silicones

 Cyclic silicones
 Cross linked silicones
The successful use of this type of glazing unit is dependent largely upon the maintaining of
the space between the two sheets of glass hermetically sealed since should this seal be
broke permitting air to enter and circulate between the sheets, the efficiency and insulating
effect of the unit would be materially reduced. When usingsuch a glazing unit, the sheet of
glass positioned to the inside as of the glazed opening is ordinarily subjected to a different
temperature than that to which the outer sheet is exposed, so that in such cases one sheet of
glass will expand or contract to a greater or lesser extent than the other sheet.
The glass sheets of a double glazing unit are also subjected to strains from changes of
internal pressure due to changes of the temperature of the air within the space between the
glass sheets and also from changes in the pressure of the outside atmosphere. The strains
set up by these varying pressure conditions co-act with the expansion or contraction of the
two sheets of glass in a tendency to break down the seal between the glass sheets.
The breaking down of the seal around the edges of the glass sheets will not only materially
lessen the insulating effect of the glazing unit but, in addition, moisture and other foreign
matter will be permitted to seep in between the sheets and to set up or promote a staining or
clouding of the inner surfaces of the glass. Further, the surfaces may become otherwise
soiled, and as it is impossible to reach them for cleaning purposes, the clarity and
transparency of the glass is ruined. Internal condensation likewise takes place between the
glass sheets which is of course highly objectionable.
Heretofore, it has been customary to maintain the glass sheets in properly spaced relation
by the use of separator strips positioned between and bonded to the said sheets around the
perimeters thereof by means of a suitable adhesive or cement applied to the strips and/or
glass. It has been proposed to make use of separator strips of felt, rubber, cork, wood, etc.
However, separator strips of this character have not proven entirely satisfactory due to the
32
diffusion of moisture and other atmospheric elements that are responsible for accelerated
weathering. That is to say, there is a tendency for moisture to seep through the separator
strips and to be diffused as water vapour upon the inner surfaces of the glass sheets.
Further, when using rubber separator strips, the sulphur or sulphur compounds from the
rubber tend to distil out and collect on the glass surfaces, producing an objectionable
appearance.
9.1 STEPS FOR MAKE A MAINTAINABLE DOUBLE-GLAZED WINDOW
Double-glazed windows are usually made from pre-fabricated glass panels. Although this is
a good design to reduce the cost and complexity of manufacture, there are drawbacks. For
example, if a double-glazed window is broken, replacing it may be very difficult and
expensive due to custom sizes, discontinued models, and companies going out of business.
Most double-glazed windows are only expected to last 10 years in moderate climates, and
less where there are temperature extremes due to the seasons, which is reason enough to be
able to maintain a window. It can be built and maintained by us and at minimal cost. If
someone breaks the glass, it can be replaced with readily available glass sheets from a
home-supply store. If it begins to collect moisture, the seals can be replaced and new
desiccant can be added.
One often-mentioned disadvantage of an air-gap double-glazed window is the convective

loss due to air circulating around in between the sheets of glass. Other gases may lower the
convective losses due to higher mass, which leads to slower diffusion. However, I think
that older windows have long since lost whatever special gas filling they may have once
had. Air-filled windows have the advantage that a normal person can replace glass and
replenish desiccant without any special equipment.
Step 1: Making the Frame
Step 2: Assemble Frame
Step 3: Cut Glass
Step 4: Assemble Window
33
9.2 DESIGN
Glass 20*12 inch

Bounding box 24*13* 1 inch
Glass Thickness 3mm
Rubber gasket 6mm
Air gap 3mm
Table 9.2 Design
34
CHAPTER 10
COST ESTIMATION
10.1 MATERIAL COST:
SL MATERIALS QUANTITY PRICE (Rs)

NO:
1 GLASS (20X12) 2 300
2 PVC FRAME 2m 300
3 RUBBER GASKET 2m 70
4 SILICON GLUE 1bottle 150
5 RIVETS 16 16
TOTAL COST 836
Table 10.1 Material Cost
35
10.2 LABOUR COST:
COST = 200 Rs
10.3 OVERHEAD CHARGES:
The overhead charges are arrived by “Manufacturing cost”
Manufacturing Cost = Material Cost+ Labour cost

= 836 + 200
= 1036 Rs.
Overhead Charges = 20% of the manufacturing cost
= 200 Rs
10.4 TOTAL COST:
Total cost = Material Cost + Labour cost + Overhead

Charges
= 836 + 200 + 200
Total cost for this project = 1236 Rs
36
CHAPTER 11
EXPERIMENTAL ANALYSIS
11.1 AIM
To find the difference in temperature while using single glass wooden frame window and
double-glazing PVC frame window
11.2 MATERIALS REQUIRED
Thermocouple, single glass wooden frame window, double glazing pvc frame window
11.3 THEORY
A thermocouple is an electrical device consisting of two dissimilar electrical

conductors forming electrical junctions at differing temperatures. A thermocouple produces
a temperature-dependent voltage because of the thermoelectric effect, and this voltage can
be interpreted to measure temperature. Thermocouples are a widely used type
of temperature sensor.
Commercial thermocouples are inexpensive, interchangeable, are supplied with standard

connectors, and can measure a wide range of temperatures. In contrast to most other
methods of temperature measurement, thermocouples are self-powered and require no
external form of excitation. The main limitation with thermocouples is accuracy; system
errors of less than one degree Celsius (°C) can be difficult to achieve.
Thermocouples are widely used in science and industry. Applications include temperature
measurement for kilns, gas turbine exhaust, diesel engines, and other industrial processes.
Thermocouples are also used in homes, offices and businesses as the temperature sensors in
thermostats, and as flame sensors in safety devices for gas-powered appliances.
37
11.4 PROCEDURE
 Press ON or OFF key to ON position. All functions show on the display, then the
thermometer is ready to use.
 Unwind the sensor cord then penetrates the stainless probe in to test substance.
 Press 0C/0F key to switch from centigrade to Fahrenheit reading.
 Data hold and maximum minimum memory: Press hold, maximum or minimum. H
will be displayed.
 Last reading will be retained.
 Press hold maximum or minimum key again. Maximum will be displayed and
minimum reading will be showed.
 Press hold maximum or minimum key again to return to normal distance.
 Tabulate the readings.
Fig 11.1 Experimental Setup
11.5 OBSERVATION TABLE
THERMOCOUPLE READINGS SINGLE GLASSING DOUBLE GLAZING
OUTER 43.3 0C 43.3 0C
INNER 42.3 0C 36.2 0C
Table 11.1 Observation Table
38
11.6 RESULT
The variation in temperature between single glass wooden frame and double glazing PVC
frame is calculated.
The difference in temperature is 6.10C.
39
CHAPTER 12
COMPARISON OF ANALYSIS RESULT AND EXPERIMENT

RESULT
From the result of analysis done over wooden frame single glass window and
double glazing PVC frame window. The rate of heat transfer in double glazing PVC frame
is lesser than the other one. A difference of .5W/M2 is obtained from the analysis result,
hence our assumption was correct and it is sure that there exists a mush high insulation
capacity for the double glazing pvc frame window. The variation in temperature between
single glass wooden frame and double glazing PVC frame is calculated experimentally and
difference in temperature between them is finded as 6.10C By comparing both results it is
clear that the product have a good insulation over heat and temperature than the
conventional single glass wooden frame window.
40
CHAPTER 13
FUTURE SCOPE
 DOUBLE GLAZING WITH NOBLE GAS

Filling noble gas between the gap of double glazing window will reduce the heat
flow and give more insulations to heat transfer
 DOUBLE GLAZING WITH CO2
Instead of normal air, co2 can be filled in the gap of double glazing window. As co2
is a greenhouse gas, it has the property of carrying more heat energy. This type of
windows can be used in cold places where thermal heaters are employed to maintain
favorable temperature. While using this type of window it prevent the loss of heat
through the window
 TRIPLE GLAZING WINDOWS

Adding additional glasses to the double glazing window triple glazing windows are
manufactured. It improves the insulation property and reduces heat flow through
windows. But economically such windows are not applicable for household
purposes and size and weight of this window be much heavier and for industrial
applications this type of window can employed
41
CHAPTER 14
ADVANTAGES, DISADVANTAGES & APPLICATIONS
14.1 ADVANTAGES
• Reduce heat transfer
• Saving of energy
• Eco-Friendly
• Recyclable
14.2 DISADVANTAGES
• Formation of water droplets between glasses
• High manufacturing cost
• Manufacturing process is difficult
• Less Life
• Weight
14.3 APPLICATIONS
• Air conditioned rooms
• Artificial snow city
• Artificial crop yielding
42
CHAPTER 15
CONCLUSIONS
The insulation strategy should be focus on the window glazing and frame at the same time,
each of them cannot be missing or ignore. On the glazing part, multi-glazing layer is much
better than single glazing, it can be found that double glazing window always got a better
insulation performance in every research. The gap between two glazing also cannot be
ignored, no matter filling in some insulation gas or air. For gas filling strategy, it is better to
use the noble gas such as argon, but if the cost of whole window system cannot be accept,
the gas can be change to some cheap compounds also with a stable chemical property
Window frame must be optimized at the same time. Frame with single material will not be
considered, and it is the same with the wooden frame, because both of them will cause
either bad insulation or inside surface condensation. Hollow inside with insulants filled
frame is the best choice, with PVC covered.
43
REFERENCES
 NAIRA, G., MAHAPATRAB, K., GUSTAVSSONB, L. (2011), ”Implementationof

energy-efficient windows in Swedish single-family houses, Applied energy”, vol.89,

Issue 1, pp.329–338
 WERNER, A., ROOS, A., NILSSON, P. (2007), “Design and evaluation of

adetection system for external water condensation on low U-value windows,

Sensors and Actuators”, Vol.138, Issue 1, pp.16–21
 K. S. KULKARNI, U. MADANAN, T. W. SIMON AND R. J. GOLDSTEIN

(2018)“Experimental Validation of a Boundary Layer Convective Heat Flux

Measurement Technique”, Heat Transfer 140(7), 074501.
 R.A. MERIC (2009),“Optimization of thermal conductivities of isotropic and

orthotropic solids”, Heat Transfer 107(3), 508-512.
 GOLDSTEIN, R. J (2007) “Heat Transfer Study in a Linear Turbine Cascade

Using a Thermal Boundary Layer Measurement Technique” ASME J. Heat
Transfer, 129(10), pp. 1384–1394.
44

1.1 Background: Fabrication and Analysis of Double Glazing Windows Using Ansys

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Fabrication and Analysis Of Double Glazing Windows Using Ansys

Computer-aided engineering (CAE) is the broad usage of computer software to aid in

2.1 CAE FIELDS AND PHASES

CAE areas covered include:

 Pre-processing – defining the model and environmental factors to be applied to it.

2.2 BENEFITS OF CAE

INTRODUCTION TO ANSYS WORKBENCH

ANSYS Workbench Mechanical can link a thermal analysis to a structural analysis,

3.1 System Requirements:

The following description shows the minimum and recommended

EXPERIMENTAL VALIDATION OF A BOUNDARY LAYER CONVECTIVE HEAT

OPTIMIZATION OF THERMAL CONDUCTIVITIES OF ISOTROPIC AND

HEAT TRANSFER STUDY IN A LINEAR TURBINE CASCADE USING A THERMAL

OPTIMUM HEATING OF PRESSURE COMPONENTS OF STEAM BOILERS WITH

HEAT TRANSFER AND EVAPORATION RATES OF SMALL LIQUID DROPLETS

horizontal heated surface. Single water droplets with a post-impact diameter of

MULTI-REGION HEAT CONDUCTION PROBLEMS BY BOUNDARY ELEMENT

A NUMERICAL STUDY OF BOUNDARY-LAYER HEAT AND MASS TRANSFER IN

5.1 BASICS OF STEADY STATE HEAT TRANSFER

• In thermal analyses, all types of bodies supported by Simulation may be used.

 Shell and line body assumptions:

Fig 5.1 Material Property

If any temperature-dependent material properties exist, this will result in a nonlinear

5.4 ASSEMBLIES – SOLID BODY CONTACTS

Fig 5.2 Solid Body Contacts

Heat Transfer Between Parts in Contact Region?

Table 5.1 Heat Transfer Between Parts In Contact Region

The contact conductance can be influenced by many factors:

Thermal Contact Notes:

5.5 HEAT LOADS

Fig 5.3 Heat Load

5.6 THERMAL BOUNDARY CONDITIONS

TEMPERATURE, CONVECTION AND RADIATION:

“h” and “Tbulk” are user-input values.

– Surface temperature, T= Tsurface

– Bulk temperature, T= Tbulk

– Difference of surface and bulk temperatures

Fig 5.4 Temperature Dependance

Fig 5.5 Convection

Select the temperature-dependency from the pull-down menu

Fig 5.6 Details Of Convection

Fig 5.7 Radiation Details

A = Area of radiating surface

F = Form factor (1)

 Provides for radiation to ambient only (not between surfaces)

• Solution options are set under the “Solutions” branch:

Fig 5.8 Outline

To solve the model, request results and “Solve”

• If a “Solution Information” branch is requested, the details of the solution output

Fig 5.9 Solution

5.10 RESULTS AND POSTPROCESSING

Various results are available for postprocessing:

MODEL AND DESIGN FOR ANSYS ANALYSIS

6.1 WOODEN FRAME WITH SINGLE GLASS

Fig 6.1 Wooden Frame with Single Glass

There is amounts kind of frame material with the U-value:

FRAME MATERIAL U VALUE

Balsa 0.055 W/m2K

Fir 0.11 W/m2K

Maple or Oak 0.166 W/m2K

Aluminum alloy (Al-Mg-Si) 0.09 W/m2K

PVC (polyvinylchloride) 0.09 W/m2K