A Brief Report of Internship AtSIEMENS CENTRE OF EXCELLENCE,PDPUGANDHINAGARByMaksud M. Chauhan(14MME028)M.tech (Thermal Engineering) Student(Semester-3)Pandit Deendayal Petroleum University

2015-16SIEMENS CENTRE OF EXCELLENCEThe Siemens-Centre of Excellence has been established at PDPU to cater the need of skilled man power in the automotive industry. The Siemens Centre of Excellence is established under an agreement between Industries Commissionerate Government of Gujarat, Siemens Industry Software (INDIA) Pvt. Ltd., Designtech Systems Ltd., India & Pandit Deendayal Petroleum University.

Fig-1: Lab facility at SIEMENS CENTRE OF EXCELLENCE

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VARIOUS CENTRE OF EXCELLENCE IN GUJARATFormerly five centres of excellence were initiated in Gujarat and they are still active in Pandit Dindayal University, L.D. Engineering College, IIIT Ram-Ahmedabad, Maharaja Sayajirao University, Vadodara and Engineering College of Surat etc.Along with these 6 centres, there will be a total of 11 centres of excellence in Gujarat will be benefited state youth in higher-education of engineering and employment.

Center of excellence at L D college of Engineering:-Government of Gujarat has sanctioned to establish Siemens Center of Excellence in Aerospace & Defense at L D College of Engineering, Ahmedabad and Memorandum of Understating has been signed between the government of Gujarat and Siemens in Presence of Honble Chief Minister at Mahatma Mandir, Gandhinagar on 11/09/2013.Centre of Excellence - Siemens has been established at L. D. College of Engineering, Ahmedabad as per MOU between1. Industries Commissionerate, Government of Gujarat,2. Siemens Industry Software (INDIA) Pvt Ltd.,3. DesignTech Systems Ltd. and4. L. D. College of Engineering, Ahmedabad .CoE has established relevant laboratories having Siemens products and Siemens Industry software applications. The equipments which have been provided by Siemens are of state-of-the-art level. The laboratories which have been established at L. D. College of Engineering, Ahmedabad under CoE, are as follows:1. Product Design and Validation Lab2. Advanced Manufacturing Lab3. Automation Lab4. Electrical Lab5. Mechatronics Lab6. Process Control & Instrumentation Lab7. CNC Programming Lab8. Rapid Prototyping Lab9. CIM Simulation Lab

Fig 2:- Lab Facility at centre of Excellence at L D college of Engineering

Center of excellence at Pandit Deendayal Petroleum Univeristy:-CoE is mainly for skill development, we train you on Industrial standard software from the range of Basics of modeling to Virtual manufacturing concepts on Siemens software and basic and advanced concepts on maintaining and commissioning power systems and motors. Improved skills of faculty & Students at Technical Institutes. Seeding Research Capability & Capacity at Institute level. Technical Education Curriculum more updated and aligned with Industry requirements. Centers of Excellence and Skill Building Centers to focus on training students in line with latest Industry needs and make them more employable. Improved placements of students in colleges. Students can compete in national employment market for better remuneration and growt

Courses at center of excellence at PDPU:-

Computer-aided manufacturing (CAM) Computer-aided engineering (CAE) Digital Manufacturing Product lifecycle management (PLM) Manufacturing Computer Integrated Manufacturing (CIM) Automation Laboratory Process Instrumentation Laboratory Electrical Laboratory

Laboratories at center of excellence at PDPU:-

1. Product Design and Validation Laboratory:-Product Design and validation Laboratory is equipped with the latest configuration to support the UG NX training Equivalent to industries standard. About Laboratory:- Product design and validation are two of the most critical stages in product development. Efficiency in product development can be significantly raised by engaging powerful tools for modeling, design and simulation. This lab is equipped with 30 workstations and is provided with most powerful tools like NX9 CAD FEMAP (Finite Element Modelling and Post Processing) NX9 Advanced Simulation Motion Analysis

2. Advanced Manufacturing Laboratrory:-Advanced Manufacturing involves the use of technology to improve products and/or processes, with the relevant technology being described as advanced, innovative, or cutting edge.This lab is equipped with 30 Workstations and provided with industries most advanced products Like NX CAM, digital manufacturing Products.

3. MCMT Laboratory:-

MCMT Laboratory has a state of the art facility for getting trained latest milling and turning CNC controller, also it has 31 axis SINUMERIK 840D SL controller which is the latest product from Siemens.

4. CIM Simulation Laboratory:-

Computer-integrated manufacturing is the manufacturing approach of using computers to control the entire production process.

Knowledge on interfacing and automation techniques Demonstrate automation combined with advanced manufacturing technology Sequence Planning, Process Planning, Shop Floor Layout Generation. Learn about Offline / On-line sequence execution techniques. Data Acquisition and processing generation. Monitoring & Virtual simulation generation for sequences

5. Rapid Prototyping Labpratory:-

Rapid prototyping is a group of techniques used to quickly fabricate a scale model of a physical part or assembly using three-dimensional computer aided design (CAD) data.

6. Process Instrumentation Laboratory:-

Process Instrumentation Laboratory is housed with different instruments like temperature measurement, level detection, pressure measurement, flow measurement etc.

7. Automation Laboratory:-

Automation lab is used to understand the role of programmable logic controllers in complex mechatronic systems, modules and subsystems.

8. Electrical Laboratory:-

Electrical Lab helps to understand the basic functions physical properties of the electrical components like motor control units and LV switchgear components and also helps to understand the role in the system.

DesignTech Systems Ltd.,India

DesignTech Systems is headquartered in Pune and has offices in 7 other cities in India in addition to two offices in USA and Canada. The company offers packages in CAD/CAE and Product Life Cycle Management to the SME Segment. DesignTech aims to cross revenues of Rs 1bn by March 2014 and expects to grow that by 100% in the subsequent three years.DesignTech specializes in providing Mechanical and product Engineeringdesign and analysis services including CAD and CAE Services. They provide CAD and 3D modeling services on all the leading CAD software such as CATIA, NX, SolidWorks, Solid Edge, Pro-E and many more. Their CAE services offerings include FEA services, CFD services, Kinematics and Multi Body Dynamics, crash test, drop test, fatigue analysis, durability tests, thermal analysis, mold flow analysis, design optimization and many such. For CAE services, we use the best in class software solutions such as HyperMesh, Radioss, OpitStruct, LS Dyna, Ansys and many more. They also provide contract engineering manpower for both onsite and offsite deployment.

Fig-3:Example of visual output given by Software

Besides CAD/CAM/CAE and PLM sector, DesignTech also offers services for the Healthcare IT segment. TheAsclepiusClinic, a hospital information management software produced by the company helps in work flow management and configurations in hospitals. It is widely used by medical practitioners and doctors, helping them do affordable healthcare management.The DesignTech CAD academy, a training vertical of the company is the authorized training and education partner of Siemens India Inc. and Altair Engineering, providing training on all their CAD/CAM/CAE and PLM suites of solutions. It has branches in Pune, Nashik and Hyderabad.Along with their partnerSiemensPLM Software, DesignTech has signed an agreement with the Gujarat Government to set up 'Centers of Excellence for Skill Development' in higher education across the state.The company was also a part of Mahindra Scorpio's development team where they worked on complex component development and vehicle integration.NissanTechno signed DesignTech Systems as their certified implementation partner in 2014 to bring Indian supplier at par with global engineering standard.In 2015, the company was selected as the 10 most promising PLM companies by Silicon India magazine.They also entered into a joint venture with Integrity Tool and Mold, the largest automotive mold, tool and die manufacturing companies inNorth Americain the same year.

Awards achieved by DesignTech:- NASSCOM Emerge 50 Award: DesignTech was adjudged amongst the top 50 Emerging Companies from India in 2010 by NASCCOM. Siemens awarded DesignTech the Best Channel Partner Award in 2013. DesignTech Systems Ltd. has been honored with a special recognition and award from NASSCOM Emerge Out Forum. Siemens PLM Software 2012 Top India Partner Award: Companies that demonstrate a commitment to providing quality service and consistent growth potential by reselling Siemens PLM Software's technology are awarded the same. Channel World Premiere 100 Award: DesignTech was recognized amongst the top 100 companies. Maharashtra State IT Award: DesignTech was honoured with Maharashtra State IT award for Engineering Services in 2010

Steps in Engineering Design Services:-Once an entrepreneur / company decides to go ahead with a product / artifact, the next step is to approach a professional engineering design services provider. Since a product designing can have a multitude of answers, there usually is an iteration involved in the design process. The design service company will handle all these cyclic iterations. Here are the basic steps that any engineering design services provider undertakes:

1. Identifying the design needs:-This process usually contains a listing of the product function and the customer requirements and expectations about the product features.

2. Gather relevant information about the product / artifact:-A lot of research goes in this step. It can involve studying the competitors products, reading of books / browsing the internet for similar products and talking to potential consumers. This step also involves identifying the loads, boundaries, conditions and forces that will be applied on the product. The product design should be such that it facilitates the smooth functioning of the products purpose under the hardest of the conditions. At the same time, the design should be optimized and should be appealing.

3. Brainstorm about possible solutions:-Since design engineering is a mix of science and creativity, there can be more than one solution for a product development. The engineering design services team discusses various options that would result in the best possible artifact. It is also important to ensure that the costs and time of development are kept to the minimum. This necessitates getting the product design right the first time.Todays advanced CAD software is intuitive and suggestive. They also contain a standard design/ or parts library which can help designers meet necessary standards and norms of design. CAE software solutions help the engineering design service team virtually analysis and simulate product designs that highlight weak areas in the design which when corrected help companies develop robust product designs.

4. Zero in on the most feasible solution:-After exploring all the What if scenarios, the companies can narrow down on the design they wish to go ahead with.This step involves selection of the best possible solution that best meet the requirements of the product / consumer and modelling a prototype using CAD / CAE software

5. Implement and test the design solution:-The advent of 3 D Printers has made prototyping easy. Most companies that provide engineering design services use a 3 D printer to actually create a 3 D object. It is then tested extensively.Creating a physical model helps companies validate the product functioning, fit, form and ergonomics. This further helps enhance product design performance.Design engineering is the driving force behind every product created for customers. Companies that specialize in this field offervalue-added services that are customized to the customer's needs.Since proper design engineering is the foundation of a successful product be it a household object or a complex architectural marvel, it is important to choose a company that has hands on experience in providing these services.

AcknowledgementAs part of curriculum it is mandatory for each student to undergo internship for 6 weeks. The purpose of internship is to provide hands on experience to the students about industries.So, seven students of my class including me, were sent to SIEMENS CENTRE OF EXCELLENCE. We are thankful to the Director, School of Technology and Prof. S.S.Kachchwaha (Dean of Faculty of Engineering and Technology) for their efforts to arrange internship for us. We are also thankful to the following mentors at SIEMENS CENTRE OF EXCELLENCE who took great efforts in resolving our doubts and helping us in learning the software. Mr. Srihariprasad Popuri Mr. Ashish Verma Mr. Ravi Simha Mr. Rakesh B. Mr. Naresh N.

Chap-1. IntroductionDuring internship we learned Siemens NX software which was formerly known as unigraphics software.About NX SoftwareSiemens NX Software is an integrated product design, engineering and manufacturing solution that helps you deliver better products faster and more efficiently.NX provides key capabilities for fast, efficient and flexible product development. Advanced solutions for conceptual design, 3D modeling and documentation. Multi-discipline simulation for structural, motion, thermal, flow and multi-physics applications. Complete part manufacturing solutions for tooling,machining and quality inspection.NX software help you design, simulate and manufacture better products faster by enabling smarter decisions in an integrated product development environment.The NX AdvantageNX is the industrys most integrated, flexible and efficient solution for product design, engineering and manufacturing. No other solution employs synchronous technology for flexible design in an open environment. No other solution integrates multi-discipline simulation so tightly into the development process No other solution offers such a full range of advanced part manufacturing applications. No other solution is integrated as tightly with Teamcenter, the worlds leading Product Lifecycle Management (PLM) platform

Modules learned in NX:- CAD Structural Analysis Thermal Analysis CFD AnalysisApart from these there are other modules in NX like CAM, Motion Simulation, etc. But due to time limitation and keeping our course curriculum in mind we learned above said modules only.The details of exactly what we learned is explained here.Chap-2.ModellingComputer-aided drafting (CAD) is the use of computer systems to assist in the creation, modification, analysis, or optimization of a design. CAD software is used to increase the productivity of the designer, improve the quality of design, improve communications through documentation, and to create a database for manufacturing.CAD output is often in the from of electronic file for print, machining or other manufacturing applications.2D Sketching:-

Figure-4: Screenshot of 2D Sketching made in NX

As far as possible the sketch must be fully constrained. Constraintscan be of two types:- Dimensional Constrain Geometric Constrain

3D Modelling:-From a sketch we can make 3D model of any object. Commands like Extrude and Revolve help us in 3D modelling.

Figure-5: Screenshot of 3D Model made in NX

Assembly:-Most of the objects are so complicated that they need to be made as individual parts and then they are assembled together.While creating the assembly in NX one have to take must care of assembly constraints like prefer touch, Align, Infer center axis, Fix axisetc. can be used to properly constrain the assembly before performing analysis.

Figure-6: Screenshot of Assembly made in NX

Chap-3 :- Structural Analysis

Structural analysisis the determination of the effects ofloadson physicalstructuresand theircomponents.Structures subject to this type of analysis include all that must withstand loads, such as buildings, bridges, vehicles, machinery, furniture, attire, soil strata, prostheses and biological tissue. Structural analysis incorporates the fields ofapplied mechanics,materials scienceandapplied mathematicsto compute a structure'sdeformations, internalforces,stresses, support reactions, accelerations.The results of the analysis are used to verify a structure's fitness for use, often savingphysical tests. Structural analysis is thus a key part of theengineering design of structures.

Chap:-4 Themal AnalysisThermal management is a major consideration for a wide range of products, including industrial machinery, automobiles and consumer electronics. The objective of any thermal management solution is to maintain a products temperature within a range that is optimal for performance. Accomplishing this may require the removal or addition of heat, either passively or in an actively managed fashion, and this can be evaluated using thermal analysis software. The NX CAE suite of solutions includes comprehensive, best-in-class thermal simulation capabilities that can help you to understand the thermal characteristics of your product and subsequently tailor your thermal management solution for optimal performance.

Projects

Project:-1Bolt Pre-Load SimulationIntroduction

This project is about creating Assembly Fem using pre-modeled CAD files and final assembly and then simulating the effect of Bolt-preload. Associative type method is used to create the Assembly Fem file and proper mesh is achieved up to required acceptance of accuracy. Advantage of FEM Assembly

The major advantage of FEM assembly is that if we make changes in any individual part then it will be automatically updated in assembly. Also if other similar part are there in assembly, then they will also get updated. So if we have big sized assembly having large number of component then assembly FEM saves our time. In our project, if we do meshing one bolt or one nut then other bolts and nuts in assembly will be meshed also.

[FEM Assembly]

[Apply the Hex Meshing On the Assembly]

The essential portion of report generated in NX is shown below.

1) Solution summary

2) material

3) Loads

4) Results

A. Displacement Analysis

[Result-Displacement Nodal]

[Path on which graph is drawn]

[Graph of Result-Displacement Nodal]

B. Stress Analysis

[Result-Stress Elemental, Von-Mises]

[Path on which graph is drawn]

[Graph of Stress Elemental, Von-Mises]

C. Strain Analysis

[Result-strain Elemental, Von-Mises]

[Graph of Strain Elemental, Von-Mises]

D. Reaction Force Analysis

[Reaction Force Magnitude]

[Path on which graph is drawn]

[Graph of Reaction force magnitude]

E. Contact Force Analysis

[Path on which graph is drawn]

[Graph of Contact force Nodal Magnitude]

F. Contact Traction Analysis

[Contact Traction Nodal Magnitude]

[Path on which graph is drawn]

[Graph of Contact Traction Nodal Magnitud

Conclusion:-By doing the Pre bolt Analysis first of all by creating Assembly Fem using pre-modeled CAD files and final assembly and then simulating the effect of Bolt-preload. Associative type method is used to create the Assembly Fem file and proper mesh is achieved up to required acceptance of accuracy.

PROJECT:-2STOOL IGS FILE SIMULATION

Introduction

This project was performed to understand the complexity encountered while we do not have standard .prt file format. As the .igs file format was given, we had to create solid model by "sew" command available in NX. Then Mid-surfaces were extracted and sheet body was constructed. Then 2D meshing was applied on mid surfaces. Before meshing "Surface Stitching" was done. Now component was ready for applying load and constraint. As shown in figure, the load was applied component-wise and 1D connection was given between point of load and top surface. The esults are visible in screenshots provided at the end of report.

ACTIVITY FLOW IN NX

As already stated in Introduction, the IGS file format was provided to us.

[IGS file provided to us for simulation]

In that format only sheet body exists instead of solid body. So to properly analyze the object we must do meshing on the mid-surfaces of the object. But that cant be extracted on sheet body. So we had to make it solid body by sew command.

Now the object was ready for extracting mid-surfaces. So automatic mid-surfaces were created and then the gap between them were removed by Extend and Trim command.

[Mid-surfaces of the object after using sew, extend and trim command]

Now surfaces were Stitched together so that they act as single sheet body. 2D meshing was done after creating different mesh collectors for different elements. Then load and constraints were applied in .sim file. And by solving it results which I obtained are provided below in form of screen-shots.

[2D mesh applied to the stool]

The essential portion of report generated in NX is shown below

1) Solution Summary

2) Material

3) Meshes

4) Results

A. Displacement Analysis

[Result-Displacement Nodal]

[Path on which Graph-1 is drawn]

[Graph-1- Displacement vs. Element (Drawn on path)]

[Path on which Graph-2 is drawn]

[Graph-2- Displacement vs. Element (Drawn on path)]

B. Rotation Analysis

[Result-Rotation Nodal] [Path on which graph is drawn]

C. Stress Analysis

[Result-Stress Elemental, Von-Mises]

[Path on which graph is drawn]

D. Reaction Force

[Result-Reaction Force, Nodal]

\E. Reaction Moment

[Result-Reaction Moment, Nodal]

Conclusion:-During the project a solid body is converted into sheet for 2D meshing. As 2D meshing yields better results and takes less solving time than 3D mesh, its a good practice to analyze 2D mesh if the Geometry permits extracting mid surfaces. Load was applied outside the geometry boundary, so 1D connection between the point of Load and top surface was required. The bottom surface was fixed and the solution was calculated. The top most portion shows maximum deformation while bottom one almost remains non-deformed. Similar results are found for stress (Von-Mises).

PROJECT:-3STRUCTURAL, MODEL AND TRANSIENT ANALYSISINTRODUCTION

In this project, dimensions of a cylinder was provided. So with help of NX a 3D model of the cylinder was generated. Then three type of analysis was performed: (1) Structural Analysis (2) Modal Analysis (3) Transient Analysis

[Hydraulic Cylinder 3D model]

Structural analysis gives us displacement and stress as result. While the Modal analysis will give us whether all parts are joined together or they are separate. It will give us the frequency of component so that we can avoid resonance with Natural frequency. As we know that when resonance occurs the weak part of the assembly fails. So we can avoid such situation by providing proper constraint. In transient analysis we divide the solution in time step and get the result in terms of varied time steps.

STRUCTURAL ANALYSIS

Before doing any kind of Analysis it is necessary to Discretize the geometry. For that we apply meshing on the object. Here for 3D model we can apply 3D tetrahedral mesh or Hex mesh. For accurate results, it is advisable to do hex mesh. So we have to go for 3D Swept mesh in NX. For swept mesh the body must be sweep- able. In Split Body option we can check whether the body is sweepable or not. If green color appears after selecting the object then it is sweepable otherwise we need to split the body to make it sweepable. Inside pressure of 250 bars was given with initially one end fixed and then two ends keeping fixed. The screenshot is given below.

Screenshot of .sim file load and constraints applied are visible

As in figure uniform hex mesh is visible. So it yields more accurate results. The results are shown below. The first figure shows nodal displacement and second one shows Von-Mises stress values.

The essential portion of report generated in NX is shown below.1) Solution Summary

2) Material

3) Mesh

4) Load

5) constraint

6) Result

A. Displacement Nodal Analysis

[Result-Displacement Nodal]

[Graph of Result-Displacement Nodal]

B. Stress Analysis

[Result-Stress Elemental, Von-Mises]

[Path on which graph is drawn]

[Graph of Stress Elemental, Von-Mises]

Modal analysis

For modal analysis we must change the solver. After performing the structural analysis we need to add new solution to it. So, in that new solution, we should select solver SOL 103 REAL EIGENVALUE. Then solve and we will get new Modal Solution. The results and parametric analysis are shown below.

1) Solution summary

2) Result :-Displacement Nodal Analysis

[Displacement Nodal Magnitude for Mode 1]

[Path on which graph is drawn]

[Graph of Displacement Vs. Element For Mode 1]

[Displacement Nodal Magnitude for Mode 7]

[Graph of Displacement Vs. Element For Mode 7]

[Displacement Nodal Magnitude for Mode 10]

[Graph of Displacement Vs. Element For Mode 10]

Transient analysis

For transient analysis we should generate a new solution. From dropdown list of solutions we have to select SOL 103 Response Simulation. The screen-shots of reports and final results are shown below. 1) Solution summary

2) Result:-Reaction force analysis

[Reaction Force-Nodal Magnitude Mode 6]

[Path on which graph is drawn]

[Graph of Reaction force Vs. Element For Mode 6]

[Reaction Force-Nodal Magnitude Mode 22]

[Graph of Reaction force Vs. Element For Mode 22]

[Reaction Force-Nodal Magnitude Mode 46]

[Graph of Reaction force Vs. Element For Mode 46]

Conclusion

The purpose of this project was to study the basics of structural, modal and transient analysis and get familiar with different solvers used in solving them. The structure analysis will give us the values of deformation and stresses at various points of the components. While the modal analysis provide us the values of frequency at different modes. This is necessary in products like automobile to avoid resonance and avoid failure of weak parts. The transient analysis will discretize the result in number of time steps and give us the results at discrete time steps. So we were able to learn three types of analysis in a single project of hydraulic cylinder.

Project:-4Thermal Analysis of Head Lamp

IntroductionThermal Analysis of a head lamp was performed in this project.Model of the lamp was given to us. The initial and boundary conditions were also provided.The filament of the lamp is generating heat at 81 W which is at steady state.The initial temperature of the lamp is taken as 500 C. and ambient air which is closer to the lamp taken as 55 C.Convection through vents and radiation between walls of lens and reflector and the filament was given. Model of Head Lamp

This is the model on which analysis is to be performed. 3D tetrahedral meshing was given on it.Here we cannot do meshing as a whole object.As it is composed of different materials. So we need to give different mesh collectors first.The material properties were provided to us so we created new material.Then meshing was done by using appropriate mesh collector.

3D Meshing on Object

Material Summary:-

Results:-Tempearture-Nodal

Result Temperature Nodal

Path On Which Graph is Drawn

Graph-Temperature Nodal vs Path Lngth

Temperature-Elemental

Result- Temperature-Elemental

Path on Which Graph is Drawn

Graph- Temperature Nodal vs Path Length

Total Heat Load

Result- Total Heat Load

Path on Which Graph is Drawn

Graph- Total Heat Load vs Path Length

Total Heat Flux

Result- Total Heat Flux

Path on Which Graph is Drawn

Graph Total Heat Flux vs Path Length

Conclusion:-By performing this Project we learnt about practical case of simultaneous conduction, convection and radiation.The filament of the lamp is source of heat and heat is convected and radiated to the surrounding medium.Thermal Analysis is very important for the successful design of components like boilers, pressure vessels etc.By performing thermal Analysis we can select the material which can sustain high temperature.Temperature at each and every point is calculated with help of the software.