DESIGN AND FABRICATION OF INDEXING

DRILL JIG FOR CYLINDRICAL WORK

PIECES
A MAJOR PROJECT SUBMITTED IN PARTIAL FULFILMENT OF THE
REQUIREMENTS
FOR THE DEGREE OF
BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING
BY
V.RAMA KRISHNA [15311A0303]

K.PRAVEEN KUMAR [15311A0305]

A.ADITYA [14311A0360]

Under the guidance of

Dr.D.KONDAYYA
(Professor of Mechanical Engineering)

DEPARTMENT OF MECHANICAL ENGINEERING

SREENIDHI INSTITUTE OF SCIENCE & TECHNOLOGY
(Approved by AICTE, New Delhi and Affiliated JNTUH: Hyderabad)
Yamnampet, Ghatkesar, Hyderabad – 501 301

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 SREENIDHI INSTITUTE OF SCIENCE ANDTECHNOLOGY
Yamnampet, Ghatkesar, Hyderabad – 501 301

CERTIFICATE

This is to certify that the project report entitled “DESIGN AND

FABRICATION OF INDEXIND DRILL JIG FOR CYLINDRICAL
WORKPIECES” is submitted by V.RAMAKRISHNA
(15311A0303),K.PRAVEN KUMAR (15311A0305) and ADITYA ADURI
(14311A0360) towards partial fulfilments of requirements for the award
of Bachelor of Technology degree in Mechanical Engineering from
Sreenidhi institute of Science and Technology (A), affiliated to JNTU-H, is a
record of bonafide work carried out during the academic year 2018-19.

The results embodied in the dissertation have not been submitted to

any other university or institute to the best of my knowledge for the award of
any degree or diploma.

Dr.D.KONDAYYA Dr. T.CH. Shiva Reddy

PROJECT SUPERVISOR HOD, MECHANICAL

DECLARATION

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 We hereby declare that the project work entitled “DESIGN AND
FABRICATION OF INDEXING DRIL JIG FOR CYLINDRICAL
WORK PIECES” is an authenticated work carried out by us for the partial
fulfilment of the award of degree of BACHELOR OF TECHNOLOGY in
MECHANICAL ENGINEERING from Sreenidhi Institute of Science and
Technology (A) affiliated to JNTU-H

The content of this report, in full or parts have not been submitted
to any other institute or university for the award of any degree.

L.V.RAMA KRISHNA (15311A0345)

K.PRAVEEN KUMAR (16315A0303)

ADITYA ADURI (14311A0359)

PLACE: Hyderabad
DATE:

ACKNOWLEDGEMENT

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 The satisfaction and euphoria that accompany the successful completion
of any task would be incomplete without the mention of the people who made it
possible .We express our deepest sense of respect, gratitude and sincere thanks to
our guide Dr. D.KONDAYYA (Professor department of Mechanical engineering),
Sreenidhi institute of Science and Technology (A), R.R district for his
encouragement and advise for the successful completion of this project.

We are grateful to Dr. T. CH. SHIVA REDDY, HOD Mechanical

Engineering department for his valuable suggestions and support for the completion
of this project.

Special acknowledgement to the Principal and Executive Director of

Sreenidhi Institute of Science and Technology for providing us the conductive
environment for carrying through our academic schedules and project.
We would like to thank all the other professors of our department for
giving us constant encouragement and helping us throughout our project.
Last but not the least we also thank our family and friends who supported
us in accomplishing the project.

V.RAMA KRISHNA (15311A0303)

K.PRAVEEN KUMAR (15311A0305)
ADITYA ADURI (14311A0360)

ABSTRACT

Nowadays development is most important to step ahead for any organization.

For that every organization has started using technology and all the possible
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action to step forward their production and sustain in market. To increase the
production, industry decreases the production time. To decrease the
production time everyone is developing new mechanism and automation. For
drilling machine to reduce the production time jig and fixtures are used.

This project is about designing a work holding component called jig in order
to hold the cylindrical workpieces for mass production of drilling operations.
This design is obtained by making several considerations in drilling holes.
This abstract involves the definition of jig and types of jigs advantages
disadvantages of this indexing drill jig. The objective of this project is to hold
the cylindrical work pieces and drill holes which are 90 degrees to each other
and equidistant from one another.

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 CONTENTS
Declaration 3
Acknowledgement 4
Abstract 5
CHAPTER 1

INTRODUCTION

1.1 Introduction
1.2 Objective of the project 9
1.2 What is jig. 9
1.3 Types of drill jigs

CHAPTER 2

DESIGN OF THE INDEXING DRILL JIG

2.1 Eiamsa-ard et al 15
2.2 Tang et al 15
2.3 Bhadouriya et al 15
2.4 Sajadi et al 15
2.5 He et al 16
2.6 Zhan get al 16
2.7 Junlin CHENG, Zuoqin Qian, Qiang Wang 16

CHAPTER 3

MODEL DESCRIPTION

3.1 Physical model 18

3.2 Mathematic model and boundary conditions 19
3.3 Numerical methods 22
3.4 Thermo-physical aspects of ɣ - AlooH and water 22
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3.5 Parameters definitions 24
CHAPTER 4
ANSYS CFD PROCEDURE

4.1 Creating a Fluent Fluid Flow Analysis System in ANSYS Workbench 26

4.2 Creating the Geometry in ANSYS Design Modeler 27
4.3 Meshing the Geometry in the ANSYS Meshing Application 28
4.4 Setting up the CFD Simulation in ANSYS Fluent 29

CHAPTER-5

SIMULATION RESULTS

5.1 Results 23
5.2 Graphs 39
5.3 Contours 43

CHAPTER-6
CONCLUSION 49

CHAPTER-7
REFERENCES 51

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 LIST OF FIGURES

Fig.1 Detail view of twisted oval tube

Fig.2 Detail view of computational mesh of twisted oval tube.

Fig.3 Detail view of computational mesh of oval tube.
Fig.4 Detail view of computational mesh of circular tube.

LIST OF GRAPHS

Graph-1 Reynolds number vs. Nusselt number

Graph-2 Reynolds number vs. Nusselt number for water and nano fluids
Graph-3 Reynolds number vs. Temperature comparison for nano fluids
Graph-4 Reynolds number vs. Temperature comparison for water
Graph-5 Reynolds number vs. pressure comparison for nano fluids

Graph-6 Reynolds number vs. pressure comparison for water

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 CHAPTER-1
INTRODUCTION
1.1 INTRODUCTION:

Heat exchangers are one of the most frequently used equipment in

chemical processes, and they can be found in petroleum, gas, and petrochemical
industries and thermal power plants on a vast scale. Considering the shrinking
energy resources and the accelerated rate of technology advancement, it seems
appropriate to improve the efficiency of heat exchangers and thus, increase the
level of performance in various industries. Twisted tubes as the parts of shell and
tube heat exchangers are applied in various heat transfer process. Twisted tube heat
exchangers were developed in the 1980s. Compared with the conventional smooth
tube, twisted tubes change the linear flow into a spiral flow inside the tubes,
resulting in a perpendicular to the main flow direction secondary flow. Twisted
oval tubes as a form of twisted tube are formed into an oval section, and two ends
of the tube remain round taking into account the assembly requirements. The
thermal performances and heat transfer enhancement of twisted tube heat
exchangers were widely investigated using experimental and numerical methods.

1.2 WHAT IS HEAT TRANSFER?

Heat transfer is the process of transfer of heat from high temperature
reservoir to low temperature reservoir. In terms of the thermodynamic system,
heat transfer is the movement of heat across the boundary of the system due to
temperature difference between the system and the surroundings. The heat
transfer can also take place within the system due to temperature difference at
various points inside the system. The difference in temperature is considered
to be ‘potential’ that causes the flow of heat and the heat itself is called as
flux.
What is the difference between thermodynamics and heat transfer?
Thermodynamics tells us:
 How much heat is transferred (δQ?)
 How much work is done (δW)
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  Final state of the system
 Heat transfer tells us:
 How (with what modes) δQ is transferred
 At what rate δQ is transferred
 Temperature distribution inside the body

1.3 MODES OF HEAT TRANSFER

CONDUCTION:
The transfer of heat between two solid bodies is called as
conduction. It depends on the difference in temperature of the hot and cold
body. Example of conduction heat transfer is two bodies at different
temperature kept in contact with each other. Another example is heating one
end of the metal like copper; due to conduction heat transfer the other end of
the metal also gets heated.
Conduction is explained by using fouries law .
FOURIER LAW:
Conduction rate equation is described by the Fourier Law:

Q =-kA∇T

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Where:
Q = heat flow, (W)
k = thermal conductivity (W/m K)
A = Cross sectional area in direction of heat flow. (m2)
∇T = Gradient of temperature (K/m) = (∂T/∂x) i + (∂T/∂y) j + (∂T/∂z) k

CONVECTION:
The transfer of heat between the solid surface and the liquid is called
as convection heat transfer. Let us considering a vessel of water being heated,
in this case heating of water due to transfer of heat from the vessel is
convection heat transfer.
Convection is explained by using Newtons laws of cooling.
NEWTON’S LAWS OF COOLING:

Q = h As ∆T

Where:
Q = heat flow (W)
h = heat transfer coefficient (W/m2 K)
As = Surface area from which convection is occurring. (m2)
∆T = =Ts − T∞ Temperature Difference between surface and coolant. (K)

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RADIATION:
Radiation heat transfer involves the transfer of heat by
electromagnetic radiation that a rises due to the temperature of the body.
Radiation does not need matter.
STEFFAN BOLTZMAN LAW:
Emissive power of a surface:
E=σεTs4 (W/ m2)
Where:
ε = emissivity, which is a surface property (ε = 1 is black body)
σ = Steffan Boltzmann constant = 5.67 x 10-8 W/m2 K4.
Ts = Absolute temperature of the surface (K)
The above equation is derived from Stefan Boltzmann law, which describes a
gross heat emission rather than heat transfer. The expression for the actual
radiation heat transfer rate between surfaces having arbitrary orientations can
be quite complex, and will be dealt with in Module 9. However, the rate of
radiation heat exchange between a small surface and a large surrounding is
given by the following expression:

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 q = ε·σ·A (Ts4 – Tsur4)

Where:
ε = Surface Emissivity
A= Surface Area
Ts = Absolute temperature of surface. (K)
Tsur = Absolute temperature of surroundings. (K)

1.4 NANO-FLUIDS
What is nano fluid?
A nanofluid is a fluid containing nanometre-sized particles,
called nano particles. These fluids are engineered colloidal suspensions of
nanoparticles in a base fluid. The nanoparticles used in nano fluids are
typically made of metals, oxides, carbides, or carbon nano tubes. Common
base fluids include water, ethylene glycol and oil.
Nano fluids have novel properties that make them potentially useful in
many applications in heat transfer, including microelectronics, fuel cells,
pharmaceutical processes, and hybrid-powered engines, engine cooling/vehicle
thermal management, domestic refrigerator, chiller, heat exchanger, in grinding,
machining and in boiler flue gas temperature reduction. They exhibit
enhanced thermal conductivity and the convective heat transfer
coefficient compared to the base fluid. Knowledge of the rheological behavior of
nano-fluids is found to be critical in deciding their suitability for convective heat
transfer applications. Nano-fluids also have special acoustical properties and in
ultrasonic fields display additional shear-wave reconversion of an incident
compression wave; the effect becomes more pronounced as concentration
increases.
In analysis such as computational fluid dynamics (CFD), nano-fluids can
be assumed to be single phase fluids; however, almost all new academic papers use
a two-phase assumption. Classical theory of single phase fluids can be applied,

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where physical properties of nano-fluid are taken as a function of properties of
both constituents and their concentrations. An alternative approach simulates nano-
fluids using a two-component model.
The spreading of a nano-fluid droplet is enhanced by the solid-like
ordering structure of nano particles assembled near the contact line by diffusion,
which gives rise to a structural disjoining pressure in the vicinity of the contact
line. However, such enhancement is not observed for small droplets with diameter
of nanometer scale, because the wetting time scale is much smaller than the
diffusion time scale.
In this work, a two-phase mixture approach is utilized to examine the
influence of nano additive shape on the fluid flow and heat transfer aspects of γ-
AlOOH nano-fluid flowing through a twisted oval tube. The γ-AlOOH (boehmite
alumina) nano additives of various shapes (i.e. cylindrical, brick, blade, and
platelet) are dispersed in water as the base fluid. The influence of the Reynolds
number and nano additive volume fraction on the nusselt number, pressure drop is
numerically studied for different nano additive shapes. It is revealed that, among
the considered nano additive shapes, the platelet shape represents the highest heat
transfer performance, while the worst performance belongs to the brick shape nano
additives.
In addition, the findings reveal that for all states, enhancing the Reynolds
number intensifies the nusselt number, pressure drop, and of the γ-AlOOH nano-
fluid. Moreover, it is found that boosting the nano additive fraction leads to an
enhancement in the nusselt number and of the examined nano-fluids. Furthermore,
the pressure drop of all the considered nano-fluids enhances with augmenting the
Reynolds number.

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 CHAPTER-2
PREVIOUS STUDIES
2.1 EIAMSA-ARD ET AL
Eiamsa-ard et al. studied the influence of three-start spirally twisted
tube combined with triple channel twisted tube insert on heat transfer
enhancement, pressure loss and thermal performance behaviours with Reynolds
number of 4000–20,000. Their results indicated that heat transfer and friction
factor increased with tape width ratio. They also found that the thermal
performance increased with decreasing Reynolds number.
2.2 TANG ET AL
Tang et al. investigated the influence of geometrical parameters on
heat transfer performance and flow characteristics of twisted tri-lobed tube and
twisted oval tube with Reynolds number of 8000–21,000. Their results showed
that twisted tri-lobed tube provided better heat transfer performance and higher
friction factor than twisted oval tube, and the heat transfer performance and
friction factor increased with the reduction of twisted pitch. They also found
that the heat transfer enhancement of twisted tri-lobed tubes was attributed to
the helical flow and secondary flow induced by twisted carved tube wall.
2.3 BHADOURIYA ET AL
Bhadouriya et al. studied heat transfer and friction factor
characteristics of air flow inside twisted square duct with Reynolds number of
600–70,000. Their results indicated that the maximum value for product of
friction factor and Reynolds number was observed for a twisted ratio of 2.5 and
a Reynolds number of 3000. They also revealed that twisted duct performed
well in laminar and also to some extent in turbulent flow region due to strong
presence of secondary flow.
2.4 SAJADI ET AL
Sajadi et al. investigated the heat transfer and flow resistance of
oil flow in alternating elliptical axis tubes. The working fluid was heat transfer
oil, and the flow’s Reynolds number ranged from 300 to 2000. Their results
indicated that decreasing the flattening and pitch length, increased heat transfer
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and flow resistance. Moreover, Sajadi et al. proposed new tube geometry called
alternating flattened tube and experimentally and numerically studied the heat
transfer and flow resistance of alternating flattened tube. Their results revealed
that the Alternating flattened tube had the best performance among the studied
tube sand could be an advantageous alternative for circular tube. The work of
Tan on twisted tube is an example of a comprehensive study of an enhancement
technique in turbulent flows for a wide range of flow conditions. They studied
convective heat transfer and fluid flow in twisted oval tubes. Their results
showed that the heat transfer coefficient and friction factor both increased with
the increasing of axis ratio, while both decreased with the increase of twisted
pitch length. They also found that the synergy angle between velocity vector
and temperature gradient was reduced and the heat transfer process was
enhanced.
2.5 HE ET AL
He et al. numerically investigated heat transfer enhancement and
pressure loss penalty for fin-and-tube heat exchangers with rectangular winglet
pairs in a relatively low Reynolds number flow. Their results revealed that the
rectangular winglet pairs could significantly improve the heat transfer
performance of the fin and tube heat exchangers with a moderate pressure loss
penalty.
2.6 ZHANGET AL
Zhan get al. studied the heat transfer characteristics of steam
condensation on horizontal twisted elliptical tubes with different structural
parameters. Their results indicated that the condensation heat transfer
coefficients for all the tubes reduced with increase of wall sub cooling, while
the enhancement factor of each twisted elliptical tube was almost constant.
They also found that a smaller twist pitch led to a lower condensation heat
transfer coefficient.
2.7 JUNLIN CHENG, ZUOQIN QIAN, QIANG WANG
Junlin Cheng , Zuoqin Qian, Qiang Wang studied heat transfer
characteristics of water flow inside twisted oval tube (TOT) for Reynolds number
in the range of 50–2000 by employing the low Reynolds k-e model. Their results

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revealed that twisted oval performs better when compared to smooth circular and
smooth oval tube.

Graph-1 Graph-2

Above shown graphs is Junlin Cheng, Zuoqin Qian, Qiang Wang studies.
One of the key findings of their studies was laminar to turbulent conversion point which
was found at Reynolds number 500. Flow is in laminar when the Reynolds number
ranges from 50-250, flow is in transition state when the Reynolds number ranges from
250-500 and the flow is in turbulent state when the Reynolds number ranges from 500-
2000.
Based their results they suggested formulas for nusselt number and friction factor
for twisted oval tube in low Reynolds number region.

The above mentioned formulas are suggested by Junlin Cheng, Zuoqin Qian, and
Qiang Wang which are valid only when the flow is laminar.

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 CHAPTER-3
MODEL DESCRIPTION

The present work deals mainly with thermal performance and heat transfer
enhancement of twisted tube in the low Reynolds number ranging from 50 to 2000.

The primary aim of the present study is

(1) To measure the heat transfer and flow resistance of twisted oval tubes of low
Reynolds number flow;
(2) To measure the transition point from laminar flow to turbulence flow;
(3) To understand heat transfer mechanism by giving the local distribution of velocity
and temperature.

3.1 PHYSICAL MODEL:

In this study, the twisted oval tube model is shown in Fig.1. The
model is divided into three parts namely inlet zone, outlet zone and heat
transfer zone. The inlet and outlet zones are smooth straight oval tubes, and the
heat transfer zone is twisted oval tube. Twisted oval tube cross-section is
elliptical, the major axis length is a, the minor axis length is b, the twisted pitch
is P, and the length of the heat transfer section is S. The flow direction at the
inlet is along the Z direction of Cartesian coordinate. In the present work, the
twisted pitch P of the original twisted oval tube is 200mm taking into account
the computing time and computer hardware configuration, the length of the
heat transfer zone of twisted oval tube is 600 mm. Moreover, to avoid any
probable back flow streams and ensure that the fully developed flow is formed
at the inlet of swirl flow region, the inlet zone length Sin and the outlet zone
length Sout are 5 times of the hydraulic diameter of the twisted oval tube.

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 Fig.1 Detail view of twisted oval tube.
(a) Cross section;
(b) iso-view of tube.
3.2 MATHEMATIC MODEL AND BOUNDARY CONDITIONS:
The working fluid is assumed incompressible fluid and physical
parameters are constant. The model governing equations in Cartesian
coordinate of fully development turbulence fluid flow as follows:
𝜕𝜌 𝜕(𝜌𝑢𝑗 )
Continuity equation: + =0 (1)
𝜕𝑡 𝜕𝑥𝑗

𝜕𝑢𝑖 𝜕𝑢𝑖 𝜕𝑝 𝜕 𝜕𝑢 𝜕𝑢𝑗

Momentum equation:𝜌
𝜕𝑡
+ 𝜌𝑢𝑗
𝜕𝑡
=−
𝜕𝑥𝑖
+𝜇
𝜕𝑥𝑗
(𝜕𝑥 𝑖 + 𝜕𝑥 ) (2)
𝑗 𝑖

𝜕𝑇 𝜕(𝑢𝑖 𝑇) 𝜕𝑢𝑖 𝜕 𝜕𝑢 𝜕𝑢𝑗

Energy equation:𝜌
𝜕𝑡
+𝜌
𝜕𝑥𝑖
= −𝑝
𝜕𝑥𝑖
+𝜆
𝜕𝑥𝑗
(𝜕𝑥 𝑖 + 𝜕𝑥 ) (3)
𝑗 𝑖

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Where
𝜌 Is the density
𝜇 Is the dynamic viscosity and
𝜆 Is the thermal conductivity
Two-equation model is one of the most widely used turbulence models,
which mainly includes the high Reynolds k-𝜀 model, the RNG k-𝜀 model, and
the realizable k-𝜀 model, etc. The high Reynolds k-𝜀 model is also known as
the standard-𝜀 model.The high Reynolds k-e model is created for fully
developed turbulent flow of high Reynolds number. The governing equations
of the high Reynolds k-𝜀 model as follows:
The k equation of high k-𝜀model:

𝜕𝑘 𝜕(𝑢𝑖 𝑘) 𝜕 𝜇 𝜕𝑘 𝜕𝑢 𝜕𝑢 𝜕𝑢𝑗
𝜌
𝜕𝑡
+𝜌
𝜕𝑥𝑗
=
𝜕𝑥𝑗
[(𝜇 + 𝜎𝑡 ) 𝜕𝑥 ] + 𝜂𝑡 𝜕𝑥 𝑖 (𝜕𝑥 𝑖 + 𝜕𝑥 ) − 𝜌𝜀 (4)
𝑘 𝑗 𝑗 𝑗 𝑖

The 𝜀 equation of high Reynolds k- 𝜀 model:

𝜕𝜀 𝜕(𝑢𝑖 𝜀) 𝜕 𝜇 𝜕𝜀 𝜀 𝜕𝑢 𝜕𝑢 𝜕𝑢𝑗 𝜀2
𝜌
𝜕𝑡
+𝜌
𝜕𝑥𝑗
=
𝜕𝑥𝑗
[(𝜇 + 𝜎𝑡) 𝜕𝑥 ] + 𝑐1 𝑘 𝜂𝑡 𝜕𝑥 𝑖 (𝜕𝑥 𝑖 + 𝜕𝑥 ) − 𝑐2 𝜌 𝑘
(5)
𝜀 𝑗 𝑗 𝑗 𝑖

𝑘2
Where 𝜇𝑡 = 𝑐𝜇 𝜌 , C1= 1.44, C2 = 1.92, Cμ = 0.09, 𝜎𝑘 = 1.0, 𝜎𝜀 = 1.3.
𝜀

The calculation result is an agreement with the experimental result of

the high Reynolds numbers flows. The effect of molecular viscosity must be
considered within the viscous layer adjacent to the wall of low Reynolds
numbers flows. To make the numerical calculation from the high Reynolds
number flows to the solid wall, the form of the high Reynolds number model
given above must be enlarged in three ways. First, the diffusion coefficient of
the governing must contain the turbulence diffusion coefficient and molecular
diffusion coefficient. Second, the relevant coefficient of governing equations
must consider the effect of the Reynolds number. Third, further terms must
account for the fact that the turbulence energy dissipation is not isotropic near
the wall. Taking into account the above factors, Jones and Launder raised the
low Reynolds number k-e model, the low Reynolds k-e model’s governing
equations as follows:
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The k equation of low Reynolds k-𝜀model:
2
𝜕𝑘 𝜕 𝜇𝑡 𝜕𝑘 𝜕𝜇 2 𝜕𝑘 1/2
𝜌 = [(𝜇 + ) ] + 𝜇𝑡 ( ) − 𝜌𝜀 − 2𝜇 ( ) (6)
𝜕𝑡 𝜕𝑦 𝜎𝑘 𝜕𝑦 𝜕𝑦 𝜕𝑥𝑗

The 𝜀 equation of low Reynolds k-𝜀model:

𝜕𝜀 𝜕 𝜇𝑡 𝜕𝜀 𝜀 𝜕𝜇 2 𝜀2 𝜕2 𝜇
𝜌 = [(𝜇 + ) 𝜕𝑦] + 𝑐1 𝑓1 𝑘 𝜇𝑡 (𝜕𝑦) − 𝑐2 𝑓2 − 2𝜇𝜇𝑡 ( ) (7)
𝜕𝑡 𝜕𝑦 𝜎𝑘 𝑘 𝜕𝑥𝑗 2

Where

𝑘2
𝜇𝑡 = 𝐶𝜇 𝑓𝜇 𝜌 (8)
𝜀

𝑓1 = 1.0 (9)
𝑓2 = 1.0 − 0.3 exp(−𝑅2 ) (10)
2.5
𝑓𝜇 = exp[− 𝑅 ] (11)
(1+ }
50

To study the impact of molecular viscosity at low Re k-𝜀model, it is

necessary to set a fine mesh near the wall to accurately reflect the dramatic
changes in the parameters of the near-wall region. Details of low Re k-𝜀 model
can be found in Jones and Launder’s research, and Launder and Sharma
improved the low Re k-𝜀model. Based on the Launder-Sharmalow Reynolds k-
epsilon turbulence model, Gorji evaluated the performance of a number of low
Reynolds number turbulence models applied to an unsteady flow inside a
closed channel and Wang investigated the heat transfer and flow characteristics
of a two-dimensional turbulent slot jet by comparison with the available
experimental data, their work revealed that the low Reynolds number model is
able to work for different flow regimes.
Boundary conditions of the fluid flow in the present work are as follows:

Inlet boundary conditions:

𝑢𝑖 = 0, 𝑣𝑖 = 0 , 𝑤𝑖 = 𝑐𝑜𝑛𝑠𝑡𝑎𝑛𝑡, 𝑇𝑖 = 300𝐾, 𝐼 = 0.16(𝑅𝑒)−1/8 (12)

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Outlet boundary conditions:
𝜕𝑢 𝜕𝑣 𝜕𝑤 𝜕𝑇
= = =0, = 0, 𝑝 = 0 (13)
𝜕𝑧 𝜕𝑧 𝜕𝑧 𝜕𝑧

Wall boundary conditions:

𝑢𝑤 = 0, 𝑣𝑤 = 0 , 𝑤𝑤 = 0, 𝑇𝑤 = 350𝐾 (14)

3.3 NUMERICAL METHODS:

The low Reynolds k-𝜀 model is employed to study heat transfer and
fluid flow in twisted oval tube. Taking into account the influence of molecular
viscosity near the wall, the low Reynolds k-e model is used. Therefore, the
grid of the simulation model near the wall needs to be generated fine. In this
study, the computational meshes were generated by using Ansys 15.0 by
importing CAD geometry. Model is divided into three parts namely the inlet
section, the outlet section and the heat transfer section. Each section meshed
respectively in order to improve the quality of the grid system. Generally, the
meshes are generated much finer in the regions adjacent to wall and much
coarser in the extended regions. The meshing grids of twisted oval tube,
smooth oval, smooth circular are shown in Fig.2, Fig.3, and Fig.4
respectively. All simulations are carried out with a computational fluid
dynamics code ANSYS Fluent 15.0. The convergence criterion for
momentum, continuity and energy equations is that the maximum residuals of
cells divided by the maximum residual of the first 5 iterations each to a value
lower than 1.0*10-5, 1.0*10-5, and 1.0*10-5 respectively.
3.4 Thermo-physical aspects of ɣ - AlooH and water:
Table-1

Thermo-Physical Properties Water ɣ - AlooH

𝜌 (kg/m3) 998.2 1018.718

𝜆 (W/(m-K)) 0.6 0.62022

μ (kg/(m-s)) 1.003*10-3 1.0285*10-3

Cp(J/(kg-K)) 4182 988.218

22 | P a g e
Fig.2 Detail view of computational mesh of twisted oval tube.

Fig.3 Detail view of computational mesh of oval tube.

23 | P a g e
 Fig.4 Detail view of computational mesh of circular tube.

3.5 PARAMETERS DEFINITIONS:

In order to facilitate presentation, the definitions of Reynolds number (Re),
average Nusselt number (Nu) and friction factor fare as follows:
𝜌 𝑣𝑖 𝐷ℎ
Re = (15)
𝜇

ℎ 𝐷ℎ
Nu = (16)
𝜆
∆𝑝
f = 𝜌 𝑣𝑚 2 𝐿 (17)
2 𝐷ℎ

Where Dh is the hydraulic diameter, Vi is the inlet velocity and Vm is the mean
velocity in the minimum flow cross-section of the flow channel. Δ𝑝 Is the
pressure drop, h is the heat transfer coefficient,𝜆 is the fluid thermal
conductivity and 𝜇 is the fluid dynamicviscosity.
The mean temperature and pressure of a cross-section are defined as:
𝑇̅ = ∬𝐴 𝑢𝑇𝑑𝐴 / ∬𝐴 𝑢𝑑𝐴 (18)

24 | P a g e
𝑝̅ = ∬𝐴 𝑝𝑑𝐴 / ∬𝐴 𝑑𝐴 (19)

As the pressure dropΔ𝑝, the total heat transfer Q, the logarithmic mean
temperature difference Δ𝑇 and the heat transfer coefficienth are defined as:
∆𝑝 = ̅̅̅̅
𝑝𝑖𝑛 − ̅̅̅̅̅̅
𝑝𝑜𝑢𝑡 (20)
̅̅̅̅̅
Q = 𝑚̇𝑐𝑝 (𝑇 ̅̅̅̅
𝑜𝑢𝑡 − 𝑇𝑖𝑛 ) (21)
(𝑇𝑤 −𝑇̅𝑖𝑛 )−(𝑇𝑤 −𝑇̅𝑜𝑢𝑡 )
∆𝑇 = (22)
ln[(𝑇𝑤 −𝑇̅𝑖𝑛 )/(𝑇𝑤 −𝑇̅𝑜𝑢𝑡 )]

𝑄
h= (23)
𝐴ℎ𝑡 ∆𝑇

Where 𝑚̇ is the inlet mass flow rate, Aht is the area of heated wall.

25 | P a g e
 CHAPTER-4
ANSYS CFD PROCEDURE

4.1 Creating a Fluent Fluid Flow Analysis System in ANSYS Workbench

Create a new fluent fluid flow analysis system by double-clicking the

Fluid Flow (Fluent) option under Analysis Systems in the Toolbox.
Selecting the Fluid Flow (Fluent) Analysis System in ANSYS Workbench

Fig.5

26 | P a g e
ANSYS Workbench with a New Fluent-Based Fluid Flow Analysis System

Fig.6

4.2 Creating the Geometry in ANSYS Design Modeler

For the geometry of your fluid flow analysis, you can create geometry in ANSYS
Design Modeler, or import the appropriate geometry file

Fig.7
Files->import external geometry->select external geometry->generate

27 | P a g e
 Fig .8
Close geometry.

4.3 Meshing the Geometry in the ANSYS Meshing Application

In the ANSYS Workbench Project Schematic, double-click the Mesh

cell in the elbow fluid flow analysis system (cell A3). This displays the ANSYS
Meshing application with the elbow geometry already loaded. You can also right-
click the Mesh cell to display the context menu where you can select the Edit...
option.

Fig 9

Create named selections for the geometry boundaries.

In order to simplify your work later on in ANSYS Fluent, you should label
each boundary in the geometry by creating named selections for the pipe inlets, the
outlet, and the symmetry surface (the outer wall boundaries are automatically
detected by ANSYS Fluent).
28 | P a g e
 Fig.10

4.4 Setting up the CFD Simulation in ANSYS Fluent

In the ANSYS Workbench Project Schematic, double-click the Setup cell

in the elbow fluid flow analysis system. You can also right-click the Setup cell to
display the context menu where you can select the Edit... option.

Fig.11

General-> check->ok

29 | P a g e
 General
Check mesh
Domain Extents:
X-coordinate: min (m) = -2.000000e-01, max (m) = 2.000000e-01
Y-coordinate: min (m) = -2.250000e-01, max (m) = 2.000000e-01
Z-coordinate: min (m) = 0.000000e+00, max (m) = 5.000000e-02
Volume statistics:
Minimum volume (m3): 1.144763e-10
Maximum volume (m3): 5.871098e-08
Total volume (m3): 2.511309e-03
Face area statistics:
Minimum face area (m2): 2.051494e-07
Maximum face area (m2): 3.429518e-05
Checking mesh..........................
Done.

Fig.12

Type –>pressure based velocity formulation->Absolute

 Models
Energy ->ON

30 | P a g e
 Fig.13

Open laminar->k-epsilon (2 eqn)

Fig.14

 Materials-> Water

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 Fig.15

 Boundary conditions Solution methods->All are second order

Fig.16

 Solution Initialization
32 | P a g e
 Fig.17

 Run calculation

Fig.18

33 | P a g e
 CHAPTER-5
SIMULATION RESULTS
In order to validate the independent of the numerical results on the grid
system, five different grid systems from very coarse mesh to very fine mesh of
twisted oval tube are investigated. It can be observed that the relative difference of
Nusselt number and friction factor both decrease with the increasing of total
element number. The relative difference between fine mesh and very mesh is much
smaller than the difference between coarse mesh and very coarse mesh. The
difference of the averaged Nu number is less than 3% among the five grid systems,
and the difference of the friction factor is less than 10%. It means that any further
increase of in the number of grids will not influence the numerical results
significantly. Therefore, the grid system of 189644 cells is chosen in numerical
simulation. Similar grid independence tests are also conducted for other cases. In
order to have a reliable grid, the velocity and the thermal boundary layers have to
be captured by the grid. According to the fluent user’s guide, the value of non-
dimensional y+ parameter should be less than one. In the present work, the value
of y+ varies from 0.021 at Re = 50 to 0.536 at Re = 2000, and the distance of the
nearest node to the tube’s wall is 0.048 mm. It reveals that the grid captures the
velocity boundary layer. To investigate the grid captures the thermal boundary
layer; the local convection coefficient and the Nusselt number are calculated and
compared with to those of the smaller grids. Preliminary tests show that the local
convection coefficient and the Nusselt number remain constant with the refinement
of the grid.

5.1 RESULTS

In this twisted oval tube, smooth oval tube and smooth circular tube are
investigated to study heat transfer enhancement characteristics of twisted oval tube.
Geometrical parameters of the studied tubes are illustrated in table.2. The cross
sections of twisted oval tube and smooth oval tube are the same pattern. The major
axis and minor axis of the cross section are 24.4 mm and 15 mm, respectively. The
twisted pitch length is 200 mm. The diameter of the smooth circular tube is 17.44
mm. The cross sectional areas of these studied tubes are the same. The length of
heated tube is 600 mm.

34 | P a g e
 Table-2.

Tubes a (mm) b (mm) a/b P (mm) S (mm) P/S

Twisted oval
24.4 15.0 1.63 200 600 0.33
tube
Smooth oval
24.4 15.0 1.63 – 600 –
tube
Smooth circular
17.44 17.44 1.00 – 600 –
tube

The heat transfer performance of the twisted oval tube and the smooth
oval tube are studied by using a computational fluid dynamics code (Fluent).
Moreover, the heat transfer performance is compared to those of smooth circular
tube. The Reynolds number based on the hydraulic diameter ranges from 50 to
2000.
Graph-1 presents the comparison of heat transfer and fig.20 presents flow
resistance between smooth and twisted tubes at low Reynolds number flow.Graph-
1(a) illustrates the relation between Nusselt number and Reynolds number of
twisted oval tube, smooth oval tube and smooth circular tube for nano fluids and
graph-1(b) illustrates for water. It can be seen clearly in graph-1(a) and graph-1(b)
that the Nusselt number trends of three type tubes is accordant. The Nusselt
number increases with the increasing of the Reynolds number. Moreover, the
correlation of the Nusselt number and Reynolds number is linear with the
Reynolds number of 750–2000. In addition, the Nusselt number of twisted oval
tube is larger than that of the smooth oval tube at the same Reynolds number,
which means the heat transfer capacity of twisted oval tube has been enhanced
compared to the smooth oval tube. What’s more, the larger the Reynolds number
is, the larger difference of the Nusselt number between twisted oval tube and
smooth oval tube is. The Nusselt number of smooth circular tube is smallest.

35 | P a g e
 30

25

20

15 oval
ellipse
10 circle

0
0 500 1000 1500 2000 2500

Graph-1(a) Reynolds number vs. Nusselt number comparison for nano fluids

25

20

15
oval
10 ellipse
circle
5

0
0 500 1000 1500 2000 2500

Graph-1(b) Reynolds number vs. Nusselt number comparison for water

Graph-1 Reynolds number vs. Nusselt number

36 | P a g e
 Graph-2 shows the connection between the friction factor and the Reynolds
number of twisted tubes for both water and nano fluids. The friction factor of
twisted tubes trends are the same. With the Reynolds number increased from 50 to
400, the friction factor decreases. But the friction factor increases when the
Reynolds number increases from 400 to 550 then decreases and again increases
from 600 to 700. When the Reynolds number comes to the range of 700–2000, the
friction factor decreases again. The change rule of friction factor interpreted above
shows that in the low Reynolds model discussed in this article, the fluid is in
laminar flow when the Reynolds number is in the range of 50–400. When the
Reynolds number is range of 400–700, the fluid is in the transition states from
laminar flow to turbulent flow. While the fluid is in turbulent flow when the
Reynolds number comes to 700–2000. Just like the Nusselt number, at the same
Reynolds number, the friction factor of twisted tube is larger than that of the
smooth tube, and the difference of friction factor between twisted and smooth
tubes becomes larger with the Reynolds number increased for nano fluids.

The friction factor of twisted tubes trends are the same. With the
Reynolds number increased from 50 to 400, the friction factor decreases. But the
friction factor increases when the Reynolds number is 1000 then decreases and for
water. When the Reynolds number comes to the range of 1000–2000, the friction
factor decreases. The change rule of friction factor interpreted above shows that in
the low Reynolds model discussed in this article, the fluid is in laminar flow when
the Reynolds number is in the range of 1000–400. When the Reynolds number is
of 1000, the fluid is in the transition states from laminar flow to turbulent flow.
While the fluid is in turbulent flow when the Reynolds number comes to 1000–
2000. Just like the Nusselt number, at the same Reynolds number, the friction
factor of twisted tube is larger than that of the smooth tube, and the difference of
friction factor between twisted and smooth tubes becomes larger with the Reynolds
number increased.

37 | P a g e
 COMPARISION OF FRICTION FACTOR FOR TWISTED OVAL
TUBES
REYNOLDS NUMBER VS FRICTION FACTOR

0.4

0.35

0.3

0.25

0.2 OVAL NANO FLUIDS

0.15 OVAL WATER

0.1

0.05

0
0 500 1000 1500 2000 2500

Graph-2 Reynolds number vs. Nusselt number for water and nano fluids

38 | P a g e
 5.2 GRAPHS

Graph-3 shows the comparison of Reynolds number vs. temperature for nano
fluids

320

318

316

314 Series1
Series2
312
Series3
310

308

306
0 500 1000 1500 2000 2500

Series 1— Circular tube

Series 2— Oval tube
Series 3— twisted oval tube
Graph-3 Reynolds number vs. Temperature comparison for nano fluids

39 | P a g e
Graph-4 shows the comparison of Reynolds number vs. temperature for water

322

320

318

316
Series1
314
Series2
312 Series3
310

308

306
0 500 1000 1500 2000 2500

Series 1— Circular tube

Series 2— Oval tube
Series 3— twisted oval tube
Graph-4 Reynolds number vs. Temperature comparison for water

40 | P a g e
Graph-5 shows the comparison of Reynolds number vs. pressure comparison for
nano fluids

45

40

35

30

25 Series1

20 Series2

15 Series3

10

0
0 500 1000 1500 2000 2500

Series 1— Circular tube

Series 2— Oval tube
Series 3— twisted oval tube

Graph-5 Reynolds number vs. pressure comparison for nano fluids

41 | P a g e
Graph-6 shows the comparison of Reynolds number vs. pressure comparison for
water

60

50

40
Series1
30
Series2

20 Series3

10

0
0 500 1000 1500 2000 2500

Series 1— Circular tube

Series 2— Oval tube
Series 3— twisted oval tube
Graph-6 Reynolds number vs. pressure comparison for water

42 | P a g e
 5.3 CONTOURS
FOR TWISTED OVAL TUBE NANO FLUIDS
PRESSURE

Re 250

Re 450

Re 1000
Pressure distributions on the middle cross-section of twisted with different
Reynolds numbers at z = 0.39 m.
43 | P a g e
 TEMPERATURE

Re-250

Re-450

Re-1000

Local temperature distributions on the middle cross-section of twisted tubes with

different Reynolds numbers at z = 0.39 m.

44 | P a g e
 VELOCITY

Re-250

Re-450

Re-1000

Secondary flow distributions on the middle cross-section of twisted oval tube with
different Reynolds numbers at z = 0.39 m
45 | P a g e
VELOCITY DISTRIBUTIONS AND STREAMLINES

Re-250

Re-450

46 | P a g e
 Re-1000

Velocity distributions and streamlines of different Reynolds number for twisted

oval tube

47 | P a g e
 CHAPTER-6
CONCLUSION

In the present work, three dimensional numerical study had been

carried out to investigate heat transfer and flow characteristics of water flow inside
twisted oval tube for Re in the range of 50–2000. The effects of the geometric
characteristics and Re variation on the performance of twisted oval tube were
conducted and the overall performance of twisted oval tube were compared with
the smooth tube. Moreover, the following major findings and conclusions are
obtained.

It can be concluded that compared with smooth tubes the heat transfer
performance of twisted oval tube has been enhanced but also with an increase of
pressure drop. Moreover, the larger the Re is, the larger difference of the Nusselt
number and friction factor between twisted oval tube and smooth tube is. The
numerical results indicate that in low Reynolds model, the fluid flow inside the
twisted oval tube is in laminar states for Re in the range of 50–400, and the fluid is
in the transition states from laminar flow to turbulent flow with the Re ranged of
450-700, while the fluid is in turbulent flow when the Re comes to 700– 2000. The
transition point is located at Re = 400 and 700 for nano fluids.

Numerical study was performed at Re = 50–2000 to investigate the

influence of geometrical parameters on fluid heat transfer and heat transfer inside
twisted oval tube. The numerical results indicate that the flattening has little effect
on heat transfer performance at Re = 100 in laminar flow. While the flattening
plays a significant role on heat transfer enhancement of twisted oval tube in
turbulent flow.
Local distributions of flow velocity and temperature provided and streamlines
inside twisted oval tube were also given. The results show that the secondary flow
is generated inside the twisted oval tube which provides longer flow path to
improve heat transfer performance. In addition, the secondary flow changes the
temperature distribution and streamlines to be different from smooth oval tube.

48 | P a g e
This can be explained that the secondary flow is generated in twisted oval tube and
the angle between the velocity vector and temperature gradient is reduced,
therefore the heat transfer process of twisted oval tube is enhanced.

From the above mentioned results it is observed that twisted oval tube
performs better when compared to other smooth tubes.

When it comes to fluid water shows more laminar range when compared
to nano-fluids but shows less heat transfer rate.

49 | P a g e
 CHAPTER-7
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