farzad mirshams, mechanical / thermal engineer, some project-samples
TRANSCRIPT
Some Samples of My Previous Design, Simulation & Test Projects, and Product Development Responsibilities
By: Farzad Mirshams, M.S.M.E.Professional Industry Experience: 25 Yrs
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M23-17inch-Rev01 HEAT LOADS
CPU Chip 48 W
GPU Chip 12 W
U3-Bridge Chip 10 W
Motherboard PCB Uniform Spread 45 W
DIMM 4 W
Display Panel 15 W
HDD 13 W
ODD 7 W
Power Supply 30 W
Fans 4W X 3 =12 W
TOTAL 196 W
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Thermal Analysis, Digeo Inc
Electronic Cooling Solutions Inc612 National Avenue, Mountain View, CA 94043 Phone: (650) 988-1155
Farzad Mirshams2/10/05
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Model Description
Physical Model
• Chassis Size (inside dimensions): 16.9 inch X 2.5 inch X 11.5 inch
• Chassis Material: 0.03 inch thick, cold rolled steel
• PCB Assembly: 0.063 inch thick FR4 / 8 layers. Effective (board averaged) in-plane, and normal to the plane conductivities modeled. Critical heat dissipating components are modeled as isothermal blocks with uniform volumetric heat generation
• Fan: Panasonic, Panaflo FBA06A12M1A, 60 X 60 X 25.5 mm / 16.6 CFM / 3.95 mmH2O / 28 dB-A / Hydro Wave Bearing. Fan curve modeled
• Hard Drive: modeled as hollow blocks with uniform heat generation inside a thin conductive outer shell, and in dry metal on metal contact with the chassis inside surface
• Power Supply: modeled as a porous “sponge” block with uniform volumetric heat generation. Flow impedance along the three axes is characterized using quadratic loss coefficients
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Fig-1: Chassis Assembly Model, Isometric View
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Fig-2: Model, Side View
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Fig-3: Grille Areas, as Modeled
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Model Description
Boundary Conditions
• Ambient Temperature: 40 C
• Chassis Top Surface: Natural convection & Radiation
• Chassis Bottom Surface: Radiation only
• Chassis Sides: Natural convection & Radiation
• Chassis Front Panel / Bezel: Insulated
• Chassis Rear Panel: Intake & Exhaust Grilles (65% open area ratio)
• Natural convection from external chassis surfaces are modeled using empirical film coefficients for horizontal, and vertical plates
• Radiation from external chassis surfaces are assumed to an infinite black body at the ambient temperature
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Model Description
Heat Loads / Power Dissipation
HD 12.5 W
PCB ASSEMBLY 70 W (Fig-4 & 5)
POWER SUPPLY 30 W
FAN <1.5 W (ignored)
TOTAL 112.5 W
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Fig-4: PCB assembly power dissipation, Top Side
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Fig-5: PCB assembly power dissipation, Bottom Side
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Model Results
• Total volumetric airflow thru the chassis: 12.1 CFM
• Mean processor heat sink's base temperature: 68.6 C
• Mean rear exhaust temperature: 52.4 C
• Temperature and air velocity plots are shown on the following slides:
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Fig-1: Chassis Assembly Model, Top View
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Model Results
• Total volumetric airflow thru the chassis: 12.4 CFM
• Mean exhaust temperature: 51.8 C
• Mean air temperature thru the fan: 45.6 C
• Mean processor heat sink’s base temperature: 69.0 C
• Mean HDD skin temperature: 53.9 C
• Total volumetric airflow thru the chassis: 12.2 CFM
• Mean exhaust temperature: 52.9 C
• Mean air temperature thru the fan: 48.4 C
• Mean processor heat sink’s base temperature: 76.8 C
• Mean HDD skin temperature: 54.9 C
Fan Blowing Air on the PCB:
Fan Pulling Air on the PCB
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Figure-1: Proposed 60K Load-Lock Chamber Model
F.Mirshams 4/28/2006
FEA Modeling of Proposed 60K Test Stand Load-Lock Chamber, Case Studies
Model Description
CASE #1:
Side Plates Thickness: 3.0 inch
Top/Bottom Plates Thickness: 3.5 inch
Lid-Cover Thickness: 3.5 inch
Lid-Cover Rib Design: NO RIBS
CASE #2:
Side Plates Thickness: 3.0 inch
Top/Bottom Plates Thickness: 3.5 inch
Lid-Cover Thickness: 3.5 inch
Lid-Cover Rib Design: Open Web, 4 inch tall
CASE #3:
Side Plates Thickness: 3.0 inch
Top/Bottom Plates Thickness: 3.5 inch
Lid-Cover Thickness: 3.5 inch
Lid-Cover Rib Design: Open Web, 5 inch tall
CASE #4:
Side Plates Thickness: 3.0 inch
Top/Bottom Plates Thickness: 3.5 inch
Lid-Cover Thickness: 3.5 inch
Lid-Cover Rib Design: Closed Web, 4 inch tall
CASE #5:
Side Plates Thickness: 3.5 inch
Top/Bottom Plates Thickness: 4.0 inch
Lid-Cover Thickness: 3.5 inch
Lid-Cover Rib Design: Closed Web, 5 inch tall
The 60K load-lock model is shown in Figure-1. Five proposed design variations were modeled, as listed below:
F.Mirshams 4/28/06
• The assumed model boundary conditions are shown in Figure-2. Only 1/2 of the actual assembly was
modeled, taking advantage of symmetry in the geometry, and boundary conditions.
• The maintenance access opening’s bolted-in cover plate is not considered structurally significant,
thus it is not included in the model.
• Load-Lock chamber and lid-cover are made of Aluminum 6061-T6, with the following properties:
– Elastic Modulus = 10.0e+6 psi
– Poisson’s Ratio = 0.33
– Density = 0.0981 lb/in**3
• The computed deformation plots, and deformation animation movies are displayed in the follow up
slides.
FEA Modeling of Proposed 60K Test Stand Load-Lock Chamber, Case Studies
Figure-2: Assumed Boundary Conditions for the proposed 60K Load-Lock FEA Model
Bolted Fixed Frame Support Areas are shown in teal color
Surface Pressure Areas are shown in blue color
Surface Pressure Areas are shown in blue color
Figure-3: A Typical FEA Mesh for the proposed 60K Load-Lock Model
ANSYS Element Types Used:1. SOLID 187 / 10 Nodes Tetrahedral / Quadratic Displacement Function2. CONTA174 & TARGE170 / Surface to Surface Contact Pair (Frictionless Non-
Bonded Contact Option)
# of Nodes: 367,956
# of Elements: 233,188
Figure-4: A Typical FEA Mesh for the proposed 60K Load-Lock Model
ANSYS Element Types Used:1. SOLID 187 / 10 Nodes Tetrahedral / Quadratic Displacement Function2. CONTA174 & TARGE170 / Surface to Surface Contact Pair (Frictionless Non-
Bonded Contact Option)
# of Nodes: 392,225
# of Elements: 248,743
CASE #3:
Side Plates Thickness: 3.0 inch
Top/Bottom Plates Thickness: 3.5 inch
Lid-Cover Thickness: 3.5 inch
Lid-Cover Rib Design: Open Web, 5 inch tall
Figure-13: Deformation
CASE #2:
Side Plates Thickness: 3.0 inch
Top/Bottom Plates Thickness: 3.5 inch
Lid-Cover Thickness: 3.5 inch
Lid-Cover Rib Design: Open Web, 4 inch tall Figure-12: Von-Mises Stress
CASE #2:
Side Plates Thickness: 3.0 inch
Top/Bottom Plates Thickness: 3.5 inch
Lid-Cover Thickness: 3.5 inch
Lid-Cover Rib Design: Open Web, 4 inch tall
Figure-8: Deformation in the Y-Direction
CASE #4:
Side Plates Thickness: 3.0 inch
Top/Bottom Plates Thickness: 3.5 inch
Lid-Cover Thickness: 3.5 inch
Lid-Cover Rib Design: Closed Web, 4 inch tall
Figure-15: Deformation in the Y-Direction
CASE #5:
Side Plates Thickness: 3.5 inch
Top/Bottom Plates Thickness: 4.0 inch
Lid-Cover Thickness: 3.5 inch
Lid-Cover Rib Design: Closed Web, 5 inch tall
Figure-22: Deformation in the X-Direction
F.Mirshams 4/16/2006
FEA Modeling of 60K/50K Ceramic Assemblies / Camlock CB Hole Size Study
• Two proposed design variations were modeled, per CAD files listed below:
• 1. CAD file: “60K 125 taper 17 shaft 8 cbored camlocks”• 2. CAD file: “50K assembly larger camlock cbores”
• Two levels of structural modeling were performed for each assembly, as follows:
• 1. The ceramic assembly was modeled as fully-bonded parts composing a single ceramic piece. Thus no possible gapping or slippage between assembly parts were allowed in the model.
• 2. The ceramic assembly was modeled as separate piece parts in non-bonded frictionless contact, using ANSYS surface to surface contact elements. Thus assembly parts could flex individually causing gaps to form.
• The assumed model boundary conditions are shown in the follow up slides. Only ¼ of the actual assembly was modeled, taking advantage of symmetry in the geometry, and boundary conditions.
• Locating pins & camlock fasteners are not considered structurally significant, thus they were not included in the model.
• Assembly parts are made of COORSTEK / AD-96 Ceramic material with the following properties:• Elastic Modulus = 44.0e+6 psi• Poisson’s Ratio = 0.21• Density = 0.135 lb/in**3
• The computed Maximum Principal stress plots are displayed in the follow up slides.
Model Description
Boundary Conditions, CAD Model: “60K 125 taper 17 shaft 8 cbored camlocks”
ANSYS Element Types Used:1. SOLID 187 / 10 Nodes Tetrahedral / Quadratic Displacement Function2. CONTA174 & TARGE170 / Surface to Surface Contact Pair (Frictionless Non-Bonded Contact Option)
Fully Bonded Model Mesh
# of Nodes: 42,689# of Elements: 24,900
Non-Bonded Model Mesh
# of Nodes: 127,683# of Elements: 80,227
CAD Model: “60K 125 taper 17 shaft 8 cbored camlocks”
Max Deformation = 0.095 inch
CAD Model: “60K 125 taper 17 shaft 8 cbored camlocks”
C/Bore size: 1.0” Diameter, 0.125” Round
Fully Bonded Model
C/Bore size: 1.0” Diameter, 0.125” Round
C/Bore size: 1.0” Diameter, 0.125” Round
CAD Model: “60K 125 taper 17 shaft 8 cbored camlocks”
Non-Bonded Model, “Gaps Allowed”
Max Deformation = 0.17 inch
Max Gap = 0.013 inch
C/Bore size: 1.0” Diameter, 0.125” Round
CAD Model: Modified “60K 125 taper 17 shaft 8 cbored camlocks”
Non-Bonded Model, “Gaps Allowed”
C/Bore size: 2.0” Diameter, 0.25” Round
C/Bore size: 2.0” Diameter, 0.25” Round
C/Bore size: 1.0” Diameter, 0.125” Round, Location Change C/Bore size: 1.5” Diameter, 0.25” Round, Location change
0.25” Round0.125” Round
Boundary Conditions, CAD Model: “50K assembly larger camlock cbores”
ANSYS Element Types Used:1. SOLID 187 / 10 Nodes Tetrahedral / Quadratic Displacement Function2. CONTA174 & TARGE170 / Surface to Surface Contact Pair (Frictionless Non-Bonded Contact Option)
Fully Bonded Model Mesh
# of Nodes: 25,285# of Elements: 14,166
Non-Bonded Model Mesh
# of Nodes: 106,222# of Elements: 66,124
CAD Model: “50K assembly larger camlock cbores”
CAD Model: “50K assembly larger camlock cbores”
Fully Bonded Model
Max Deformation = 0.12 inch
CAD Model: “50K assembly larger camlock cbores”
Non-Bonded Model, “Gaps Allowed”
Max Deformation = 0.22 inch
Max Gap = 0.019 inch