1.

Show the exploded and assembly drawings (with balloon numbering and part list table)
together with the 2D vital dimensions of your designed heating element.

Figure 1 Exploded View 3D

Figure 2 2D
2.Show the calculations for appropriate heating element diameter and length with or without
number of turns and fins if any.
Numerical Calculations:
Given,
Heat Power Rating (P) = 500W
Temperature Outlet = 322.1K
Temperature inlet = 295 K
Specific Heat Capacity of water = 4180 J/kg K
Density of water = 990 kg/m3
Velocity initial (Vi) = 1.2 m/s
Coefficient of natural convection (h) = 370 (Ts – T)
Let us consider, surface temperature of each heater when steady state condition, (T s) = 800K

T 1 +T 2
Now, Mean temperature (Tm) = = 308.5K
2
Now, Let the heating element be of nichrome material thus,
ε =0.9 e= 1.09 ×10−6 Ωm
k = 0.6 p= 500W
V2
Resistance, R= = 96.8 Ω
P
Now,
el
R=
A
1.09× 10−6 ×l ×4
96.8 =
π d2
1.09× 10−6 ×l ×4
303.9 =
d2
6 l
or, 82.8 ×10 =
d2
or, l=d2 ×82.8 × 106 … … …..(1)
Since, we have,
Coefficient of natural Convection
 1
3
h=370(T s−T )
1
¿ 370(800−308.5) 3
=2919.1 W/m2k
Heat Radiated,
H=5.722 ×0.9 × 0.6 [ ( 8004 −308.54 ) ] × A ×
¿ 12371.9 × πDL
Here,
Since three electric heaters are present heat dissipation should be taken (3 Power)
According to Newtons law of cooling
Heat dissipated (Q)= h A (Tw-Ts) +H
4
Or, 3 ×500=A (T −T ) 3 + ¿H
w

Or, 1500 ¿ πDL×17432 ×108 +12371.9 π

3.31 ×10−3 8
Or, D= × 7.71× 10 …..(2)
l
From equation (1) and (2), we get
D= 20.73 mm
L= 917.401 mm
Here, we have concluded that the Diameter of the required heating element is 20.73mm and the
length is 917.41 mm. The length of the heating element is bend symmetrically in U shape, that
would fit in the heat chamber of 400mm.
3. Show all boundary conditions specified in your model and meshing information
Here, the inlet water enters to the heating chamber with the velocity of 1.2 m/s and the
temperature of 295 K. The heating element surface temperature is 800K. The water of 322.1K
temperature is obtained from the outlet. The fluid used in the internal flow is water of density
and specific heat of ρ=990 kg/m3 and c = 4180 J/kg K. The coefficient of natural convection is
h=370(Ts - T)1/3 and the value the convection is applied to the heating element surface of value
2919.1 W/m2K. The outlet is pressure outlet.

Figure 3 Boundary condition

4. The fluid streamlines flow

Figure 4 Streamline flow

5. The fluid static pressure contour diagram and the pressure drop obtained

Figure 5 Lateral

Figure 6 Isometric
As, we can see at static pressure is more at the inlet pipe and the outlet pipe as the diameters of
the pipes as less compared to the heat chamber. The maximum pressure drop is 380 N/m2.
6. The fluid temperature contour diagram

The temperature of water increases when travelling towards the leftmost heat chamber. The
temperature of water can be analyzed by seeing the section plane of the water.