‫‪ALEXANDRIA UNIVERSITY‬‬

‫‪FACULTY OF ENGINEERING‬‬
‫‪MECHANICAL ENGINEERING DEPARTMENT‬‬
‫‪THERMAL ENGINEERING BRANCH‬‬

‫‪HEAT TRANSFER PROJECT‬‬

‫‪NO.‬‬ ‫‪NAME‬‬ ‫‪ID‬‬

‫‪1‬‬ ‫أيمن محمود جمعة بسيوني‬ ‫‪19015504‬‬
‫‪2‬‬ ‫محمد أشرف محمد العقبي‬ ‫‪19016248‬‬
‫‪3‬‬ ‫حسن السيد محمد علي مطاوع‬ ‫‪19015598‬‬
‫‪4‬‬ ‫محمد أيمن محمد عبد الفتاح‬ ‫‪19016251‬‬
‫‪5‬‬ ‫أحمد محمد أحمد الزهري‬ ‫‪19015315‬‬
‫‪6‬‬ ‫اسالم محمد محمود عبدالعال‬ ‫‪19015148‬‬
‫‪7‬‬ ‫محمد أشرف صالح شيبون‬ ‫‪19016305‬‬
‫‪8‬‬ ‫أسامة عادل احمد سليمان عبد المولى‬ ‫‪19015399‬‬
‫‪9‬‬ ‫عمر جمال عبدالحميد احمد‬ ‫‪19016061‬‬
‫‪10‬‬ ‫‪ 19016422‬محمد عبدالغني عبدالحليم ابراهيم غانم‬

‫‪MODELING AND SIMULATION ON‬‬

‫‪ANSYS AND COMSOL‬‬

‫‪THIRD-YEAR MECHANICAL ENGINEERING‬‬

‫‪2023‬‬

‫‪1|Page‬‬
Table of Contents
CASE 1...................................................................................................... 4
GIVENS ................................................................................................................................................... 4
MODELING OF THE PROBLEM ....................................................................................................... 4
ANSYS SOLUTION ............................................................................................................................... 5
SOLUTION PROCEDURE ............................................................................................................... 5
1 – inserting our dimensions into ansys design-modeler ................................................................. 5
2 – Meshing .......................................................................................................................................... 5
3 – inserting data from our problem (Start with Velocity = 20 Km/hr ) ........................................ 6
4 – Calculations and iterations ........................................................................................................... 7
Results for only V = 20 Km/hr ........................................................................................................... 7
5 – Final Results and Graphs ............................................................................................................. 9
(Q1) ..................................................................................................................................................... 10
(Q2) ..................................................................................................................................................... 11
(Q3) ..................................................................................................................................................... 12
COMSOL SOLUTION ......................................................................................................................... 14
(Q1) ..................................................................................................................................................... 14
(Q2) ..................................................................................................................................................... 14
(Q3) ..................................................................................................................................................... 15
INTRODUCTION (FOR MANUAL SOLUTION) .......................................................................... 17
MODEL DEFINITION ........................................................................................................................ 17
COEFFICIENT OF DRAG CORRELATION .................................................................................. 17
MANUAL SOLUTION ........................................................................................................................ 18
EES SOLUTION ................................................................................................................................... 18
(Q4) ..................................................................................................................................................... 18
(Q4-1) ................................................................................................................................................. 18
EES CODE ........................................................................................................................................ 18
(Q4-2) ................................................................................................................................................. 20
(Q4-3) ................................................................................................................................................. 21
EES CODE ........................................................................................................................................ 21
MATLAB SOLUTION ......................................................................................................................... 23
MATLAB CODE .............................................................................................................................. 23
(Q4) ..................................................................................................................................................... 24
2|Page
 (Q4-1) ................................................................................................................................................. 24
(Q4-2) ................................................................................................................................................. 24

Second Problem ..................................................................................... 25

GIVENS .................................................................................................................................................... 25
"Material A" ............................................................................................................................................ 28
"Material B" ............................................................................................................................................ 30
"Material C" ............................................................................................................................................ 32
"Material D" ........................................................................................................................................... 34
"Material E" ............................................................................................................................................ 36
Cost Analysis ........................................................................................................................................... 38

3|Page
 CASE 1
GIVENS
Length = 8 m
Width = 2.5 m
q = 1000 W/m^2
αx = 0.2
T∞ = 20 𝐶𝑒𝑙𝑒𝑠𝑖𝑢𝑠
U∞ = 20 𝐾𝑚/ℎ𝑟

MODELING OF THE PROBLEM

4|Page
 ANSYS SOLUTION
SOLUTION PROCEDURE
1 – inserting our dimensions into ansys design-modeler

2 – Meshing

5|Page
3 – inserting data from our problem (Start with Velocity = 20 Km/hr )

6|Page
4 – Calculations and iterations

Results for only V = 20 Km/hr

Cartage top surface temperature
Ts_avg = 306.21713 Kelvin

7|Page
Cartage top surface Heat transfer coefficient (h)
h_avg = 16.701696 W/m^2.k

Cartage top surface Skin friction coefficient (𝐂𝐟 )

𝐂𝐟 = 0.003171027

8|Page
5 – Final Results and Graphs
CFD POST

Parameter set

9|Page
Table of results from Ansys
Name Velocity Ts_avg h_avg_ F_friction
Cf
Units m/s Km/h k w/m^2.k N
DP 0 5.56 20 306.217 16.7017 0.003171027 1.180255469
DP 1 11.11 40 300.449 29.2952 0.002980834 4.429884326
DP 2 16.67 60 298.301 40.9229 0.002824416 9.449882341
DP 3 22.22 80 297.159 51.9553 0.002705052 16.08015208
DP 4 27.78 100 296.442 62.6096 0.002610131 24.25231907
DP 5 33.33 120 295.948 72.9445 0.002532293 33.86968278
DP 6 38.89 140 295.584 83.0585 0.002466499 44.91416961

(Q1) The effect of truck velocity from 20 to 140 km/h on the cartage top surface average
temperature and overall convection coefficient.

350

306.217 300.449 298.301 297.159 296.442 295.948 295.584

300

250

200

150

100 83.0585
72.9445
62.6096
51.9553
40.9229
50 29.2952
16.7017

0
0 20 40 60 80 100 120 140 160
Air Velocity (m/s)

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(Q2) The effect of truck velocity from 20 to 140 km/h (use step of 20 km/h) on the friction
force on the top surface and overall skin friction coefficient.

U VS F_friction
50
44.91416961
45

40
33.86968278
35

30
F_fr (N)

24.25231907
25

20 16.08015208
15
9.449882341
10
4.429884326
5 1.180255469
0
0 20 40 60 80 100 120 140 160
Air Velocity (m/s)

U VS Cf
0.0035
0.003171027
0.002980834
0.003 0.002824416
0.002705052
0.0026101310.002532293
0.002466499
0.0025

0.002
Cf

0.0015

0.001

0.0005

0
0 20 40 60 80 100 120 140 160
Air Velocity (m/s)

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(Q3) Plotting of the viscous boundary layer against the cartage length for 20 km/h truck
velocity.

Velocity distributions at [20 Km/h].

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Velocity Contour

Temperature Contour

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 COMSOL SOLUTION
(Q1) The effect of truck velocity from 20 to 140 km/h on the cartage top surface average
temperature and overall convection coefficient.

(Q2) The effect of truck velocity from 20 to 140 km/h (use step of 20 km/h) on the friction
force on the top surface and overall skin friction coefficient.

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(Q3) Plotting of the viscous boundary layer against the cartage length for 20 km/h truck
velocity.

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16 | P a g e
INTRODUCTION (FOR MANUAL SOLUTION)
The heat transfer coefficient derived from the simulation is validated against Nusselt number-
based correlation functions using this model of turbulent airflow over a flat plate. The modeling
findings and experimental data correlate well.

MODEL DEFINITION
A plate of length L is transfer heat at a constant heat flux q of 𝟐𝟎𝟎 𝑾/𝒎𝟐 by convection and placed
in airflow with different velocities from 20 to 140 km/hr (step of 20 km/hr) and temperature
𝑻∞ = 𝟐𝟎 °𝑪
The left boundary of the domain is the inlet, the right boundary is the outlet, and the bottom
boundary is the truck surface.

MODEL DEFINITION
The following Nusselt number correlations are used to validate the numerical results.The Nusselt
number 𝑵𝒖𝒙 at the position 𝒙 along the plate is defined as follows:

COEFFICIENT OF DRAG CORRELATION

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 MANUAL SOLUTION
EES SOLUTION
(Q4) comparison between the numerical results of (1), (2), and (3) obtained from the Ansys
software and comsol multi-physics software and the manual solution from empirical
equations using EES software.
(Q4-1) The effect of truck velocity from 20 to 140 km/h on the cartage top surface average
temperature, overall convection coefficient, the friction force on the top surface, and
overall skin friction coefficient.

EES CODE
L =8 [m]
W = 2.5 [m]
A=L*W
q_solar = 1000 [W/m^2]
abs = 0.2
q=q_solar *abs
T_infinity = 20 [°C]
q= h*(T_avg-T_infinity)
rho = density(Air,T=T_f,P=101.325 [KPa])
Pr = prandtl(Air,T=T_f)
mu=viscosity(Air,T=T_f)
k=conductivity(Air,T=T_f)
U_infinity =V*5/18
Re_L = (rho * U_infinity* L )/ mu
T_f = 0.5*(T_avg+T_infinity)
Nuh_L= (0.0385*(Re_L)^(0.8)-754.6)*Pr^(1/3)
Nuh_L= (h*L)/k
Cf_avg=(0.074/(Re_L)^(1/5))-(1742/Re_L)
Ff=0.5*Cf_avg*rho*A*(U_infinity)^2

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Graph the average temperature, overall convection coefficient & velocity

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(Q4-2) The effect of truck velocity from 20 to 140 km/h (use step of 20 km/h) on the friction
force on the top surface and overall skin friction coefficient.

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(Q4-3) Plotting of the viscous boundary layer against the cartage length for 20 km/h truck
velocity.

EES CODE
Function delta ( x )
U_infinity = 20*5/18
T_f = 27.225 [°C]
rho = density(Air,T=T_f,P=101.325 [KPa])
Pr = prandtl(Air,T=T_f)
mu=viscosity(Air,T=T_f)
Re_x = rho * U_infinity * x / mu
If (Re_x<5e5) Then
delta = 5 * x / Re_x^(0.5) *1000
Else
delta = 0.37 * x * Re_x^(-1/5) *1000
Endif
End
Duplicate z = 1,800
delta[z] = delta(z/100 [mm])
End
Duplicate y = 1,800
x[y] = y
End

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Graph the viscous boundary layer & velocity

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 MATLAB SOLUTION
MATLAB CODE
close all;
clear all;
clc;
Length=8;
width=2.5;
q=200;
T_air=293;
T_s=323;
i=0;
for U=(20:20:140);
i=i+1;
Velocity(i)=U
for n=1:3;
T_f=(T_air+T_s)/2;
[Rho,k,mu,pr]=air(T_f,1013.25,[],'rho','k','mu','pr');
l=0;
for x=0.1:0.1:Length;
l=l+1;
Re_x=(Rho*U*x)/mu;
if Re_x<5*10^5;
Nu_x=0.453*Re_x^(0.5)*pr^(1/3);
else;
Nu_x=0.0308*Re_x^(4/5)*pr^(1/3);
end
h_x(l)=(Nu_x*k)/x;
end
h_avg(i)=mean(h_x);
Ts_avg(i)=(q/h_avg(i)+T_air);
Ts=Ts_avg(i);
end
end
yyaxis left
plot(Velocity,h_avg,'b','linewidth',2)
xlabel('Truck velocity (km/hr)','fontsize',16)
ylabel('h_avg','fontsize',16)
ylim([0 150])
yyaxis right
plot (velocity,Ts_avg,'r','linewigth',2)
ylabel('Velocity,_avg','b','fontsize',16)
ylim([0 400])
legend('H_T cofficant (h_avg)','surface Temperature{Ts_avg}','fontsize',16)
grid on
yyaxis left
plot(Velocity,FD,'b','linewidth',2)
xlabel('Truck velocity (Km/hr)','fontsize',16)
ylabel('FD_avg','fontsize',16)
ylim([0 50])
yyaxis right
plot(Velocity,vf_avg,'r','linewidth',2)
ylabel('Velocity,cf_avg','b','fontsize',16)
ylim([0 1])

23 | P a g e
(Q4) comparison between the numerical results of (1), (2), and (3) obtained from the Ansys
software and comsol multi-physics software and the manual solution from empirical
equations using EES software.
(Q4-1) The effect of truck velocity from 20 to 140 km/h on the cartage top surface average
temperature, overall convection coefficient, the friction force on the top surface, and
overall skin friction coefficient.

Graph the average temperature, overall convection coefficient & velocity

(Q4-2) The effect of truck velocity from 20 to 140 km/h (use step of 20 km/h) on the friction
force on the top surface and overall skin friction coefficient.

24 | P a g e
 Second Problem

GIVENS
Length = 1 m
Radius of pipes = 6 mm
Temperature surrounded =20 co
Heat transfer coefficient = 5 𝑊/𝑚2. ℃

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Show the variation of Qloss with insulation thickness (𝛿𝑖𝑛𝑠)
[plot 𝛿𝑖𝑛𝑠 on the x-axis and Qloss on the y-axis]

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27 | P a g e
The thickness of insulation to reduce the heat loss by
50% for each of the materials provided
EES Code
"MaterialA"
k=0.5 [w/m.k]
r_1=0.03 [m]
h=5 [w/k.m^2]
L=1[m]
T_1=100 [c^o]
T_2=25 [c^o]
Rth_ins=ln(r_ins/r_1)/(2*pi*k*L)
Rth_conv=1/(h*2*pi*L*r_ins)
Rth=Rth_ins+Rth_conv
Q= 35.34 [w]
Q=(T_1-T_2)/Rth
delta=r_ins-r_1
The Solution

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Parametric Table

The relation between heat transfer and delta

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EES Code
"Material
B"
k=0.4 [w/m.k]
r_1=0.03 [m]
h=5 [w/k.m^2]
L=1[m]
T_1=100 [c^o]
T_2=25 [c^o]
Rth_ins=ln(r_ins/r_1)/(2*pi*k*L)
Rth_conv=1/(h*2*pi*L*r_ins)
Rth=Rth_ins+Rth_conv
Q= 35.34 [w]
Q=(T_1-T_2)/Rth
delta=r_ins-r_1 .
The Solution

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Parametric Table

.
The relation between heat transfer and delta

31 | P a g e
EES Code
"Material C"
k=0.3 [w/m.k]
r_1=0.03 [m]
h=5 [w/k.m^2]
L=1[m]
T_1=100 [c^o]
T_2=25 [c^o]
Rth_ins=ln(r_ins/r_1)/(2*pi*k*L)
Rth_conv=1/(h*2*pi*L*r_ins)
Rth=Rth_ins+Rth_conv
Q= 35.34 [w]
Q=(T_1-T_2)/Rth
delta=r_ins-r_1
The Solution

32 | P a g e
Parametric Table

The relation between heat transfer and delta

33 | P a g e
EES Code
"Material D"
k=0.2 [w/m.k]
r_1=0.03 [m]
h=5 [w/k.m^2]
L=1[m]
T_1=100 [c^o]
T_2=25 [c^o]
Rth_ins=ln(r_ins/r_1)/(2*pi*k*L)
Rth_conv=1/(h*2*pi*L*r_ins)
Rth=Rth_ins+Rth_conv
Q= 35.34 [w]
Q=(T_1-T_2)/Rth
delta=r_ins-r_1

The Solution

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Parametric Table

The relation between heat transfer and delta

35 | P a g e
EES Code
"Material E"
k=0.05 [w/m.k]
r_1=0.03 [m]
h=5 [w/k.m^2]
L=1[m]
T_1=100 [c^o]
T_2=25 [c^o]
Rth_ins=ln(r_ins/r_1)/(2*pi*k*L)
Rth_conv=1/(h*2*pi*L*r_ins)
Rth=Rth_ins+Rth_conv
Q= 35.34 [w]
Q=(T_1-T_2)/Rth
delta=r_ins-r_1

The relation between heat transfer and delta

36 | P a g e
Parametric Table

The relation between heat transfer and delta

37 | P a g e
Cost Analysis
Volume of insulating material = π )r_ins2 – r_pipe2) * L_pipe [m3]

Total Cost = Volume of insulating * cost [L.E]

Material Volume (m3) Total Cost (L.E)

A 1730 1.73*106

B 131.385 3.94*105

C 8.467 42337.1
D 0.47427 3794.19
E 4.317*10-3 64.76

Comment

We will choose the E material that reduces losses by 50% at the

lowest cost, unlike the rest of the materials, which reduces
losses by the same percentage, but at a higher cost.

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