cm_pwr drop test structural fea. objectives simulate drop test from 3 feet using algor simulation...

CM_PWR Drop TestStructural FEA

ObjectivesSimulate Drop Test from 3 feet using Algor

simulation

Produce an accurate Finite Element Analysis of the event

MaterialsTest 1 - Aluminum

Simulated ForcesTest 1 & 2

Analysis

Analysis

Results Maximum Principal Stress – 1235 psi

6061- O temper AluminumMax Yield Strength ~ 8000 psi

6061- T6 AluminumMax Yield Strength ~ 35000 psi

MaterialsTest 2 - Delrin

Analysis

Analysis

Analysis

Results Maximum Principal Stress – 1370 psi

Delrin 500MP NC010Max Yield Strength ~ 10200 psi

CM_PWR Thermal Test

Structural FEA

Simulated Test ConditionsTransient Thermal Analysis

3 “Hot Spots” 0-6 min – 15 watts of Heat Generated 6-7 min – ramp up to 45 watts of Heat

Generated 7-8 min – Full 45 watts of Heat Generated

0 60 120 180 240 300 360 420 4800

10

20

30

40

50

Seconds (s)

Heat

Gen

era

ted

(W

)

Simulated Test Conditions Initial Temperature – 32º C (90º F)

Convection Coefficient – 3.2 J/(sºCm2)

Surrounding air at 32º C Density – 1.2096 kg/m3

Prandtl No. – 0.71 Thermal Conductivity – 0.0257 W/mºC

ResultsTest 1 –Aluminum Body & Base

ResultsTest 2 – DuPont Delrin Body & Aluminum Base

Alternate DesignHeat sink on the bottom of the base plate

5º C reduction at 6 minutes 12º C reduction at 8 minutes 48 in2 increase in area 0.038 lbm mass addition

ResultsTest 3 – DuPont Delrin Body & Aluminum (w/ Fins) Base