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Mechanics Of Materials
LAB REPORT# 07
Submitted to: Eng. Wahad Ur Rehman
Submitted by:ZAIN ULLAH
Registration Number: 20PWMCT0761
Lab Report Rubrics:

Below Basic Student’s

Criteria Excellent (4) Proficient (3) Basic (2)
(1) Score
Report is
Report is as Report is
mostly as per the Sections/
per the disorganized
To organize the lab guidelines and Steps are not
guidelines. All and follows
report and practice most ordered and
sections/steps are some guidelines
the writing skills as sections/steps are Report is not
clearly organized but most of the
per the guidelines ordered well but as per the
in a logical guidelines are
requires minor guidelines
order. missing
improvements.
The report
completely
discusses the The report The report
The report
required discusses the is totally
discusses the
To discuss the actual experiment/lab experiment/lab irrelevant to
required
experiment/task work in own work but have the
experiment/lab
words with some irrelevant experiment/la
work
relevant information b work
additional
information
Calculations Most data
Calculations and data analysis and
and data analyses were performed observations
Calculation
To perform were performed accurately, but were recorded
s and data
calculations and data clearly, minor errors were adequately, but
analyses of lab
analysis concisely, and made both in with several
were missing
accurately, with calculations and significant
correct units. in applying errors or
correct units omissions.
To present results in Graphs, if Graphs, if Graphs, if Major
the form of graphs necessary, were necessary, were necessary, were components of

ZAIN ULLAH 20PWMCT0761

 drawn accurately
and neatly and drawn but lab were
drawn adequately
were clearly inadequately. missing
labelled.
Lab 01: Introduction to Comsol Multiphysics Software
Objective:-
 To Learn the basic of COMSOL Multiphysics.
 To learn how to model a real time system in COMSOL Multiphysics
 To Learn how to simulate a real time system in COMSOL Multiphysics
Main features:-

 Material Library.
 Multiphysics in single simulation process.
 Model Library.
 Link to various softwares such as AUTOCAD, Solidwork, MS Excel,
MATLAB and many others.
 Online webinar.
 Multi-plot features.

Installation Steps:-
 Click on setup and select Language.
 Accept to agreements and click on the browse button to select license file.
 To select license file, come to crack folder or solid squad folder.
 Select the destination folder.
 Uncheck updates.
 Click on install and wait for completion.

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 Figure 9 : 1 Select Language

Figure 9 : 2 Select New Installation

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Figure 9 : 3 Select License file

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Figure 9 : 5 Select Destination folder

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 Figure 9 : 7 Click on Install

Modelling and Simulations Steps:-

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 Start
Stop Setup Model
Environment

View Select
Results Multiphysics

Run Select
Simulation Study

Select Creating
Study Type Geometry

Creating Adding
Mesh Initial Material
Boundary
Conditions

Setup Model Environment:

1. At the start we have two options, Model Wizard and Blank Model. In
Model Wizard, we have mostly built in features. In Blank Model, we will
do everything ourselves.

Figure 9:8 Setup Model Environment

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 2. Select Space Dimensions
Select 3D and Done

Figure9:9 Setup Model Environment

3. Select physics
We can add more than one physics and also remove it.

Figure 9:10 Select Physics

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 4. Select Study

Figure 9:11 Study Selection

5. Creating Geometry
Select units, shape size and Position.

Figure 9:12 Creating Geometry

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 6. Adding Materials

Figure 9:13 Adding Materials

7. Initial and Boundary Conditions

Right Click on physics and select one of the conditions.

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 Figure 9:14 Initial and Boundary Conditions

8. Creating Mesh

Figure9: 15 Mesh

9. Run Simulation

Figure 9:16 Run Simulation

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10.View Results

Figure 9:17 View Results

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Application of Comsol Mlti Physics:-

1. Predict and Minimize Noise in Transformers:-

 Transformers are great for safely connecting high-voltage lines with local
power substation, but they’re not silent — and just as high voltages are
dangerous, so are high levels of noise. ABB Corporate Research Center
(ABB CRC) found that simulation is effective for developing new and
optimizing existing power transformer equipment with noise regulations in
mind. In particular, they needed to analyze the inner workings of their
transformers, because the noise stems from both the core and the oil tank.

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 Additionally, to produce simulations that accurately represent the real
world, the team at ABB CRC had to couple electromagnetics, acoustics,
and structural mechanics in a single environment. That’s why they turned
to COMSOL Multiphysics. Now, the team is able to optimize their
transformer designs with minimal hum before manufacturing them.

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Left: A transformer made of a metal core with coils of wire wound around
different sections, protected by an enclosure, and an insulating oil inside. Right:
Acoustic analysis of the sound pressure field around the core and transformer.

2. Plan Underground Cable Networks Accurately and at Low Cost:-

 Safe. Reliable. Affordable. Managing the electric grid involves meeting all
of these requirements. National Grid, which services homes and businesses
in England and Wales, needs accurate cable ratings when planning where
to lay new cable, especially in older sections that have been repaired using
different materials in the same cable line. Managing underground cable
networks requires a deep understanding of how surrounding soil, cable age,
repairs, and proximity of other cables will affect performance.
 However, testing these high-voltage systems is difficult due to their
enormous size and the fact that cables have to be analyzed in context rather
than in isolation. Finite element analysis (FEA) is up to the task: By
modeling cable components with COMSOL Multiphysics, National Grid
can ultimately make good decisions about where to lay new cables and how
to best repair old ones — thereby minimizing installation costs.

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Left: A section of underground cables. Right: A model showing the normalized
airflow profile of the cross section of a tunnel containing high-voltage cables.

3. Manage the Grid More Efficiently:-

 Cable health assessment is vital to keeping the electric grid running

smoothly. In addition to using traditional testing equipment (such as
infrared, ultraviolet, and partial discharge), the assessment process has to
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 account for cable structure and material, impurities in the cable, voltage
fluctuation, and operating conditions and environments. Multiphysics
simulation leads to more accurate cable health assessments, but how do you
get these simulations out in the field where the health assessments take
place and repair decisions are made?
 At Wuhan NARI Group Corporation (NARI) of the State Grid Electric
Power Research Institute in China, the answer to this question is to turn
multiphysics models into simulation applications and give them to the field
technicians. The Application Builder in COMSOL Multiphysics allows
simulation engineers to wrap sophisticated models in easy-to-use interfaces
with limited input fields. Armed with a custom application that NARI calls
the Cable Condition Analysis Expert System, field technicians can then
assess cables confidently based on accurate simulation results generated
from simple data entry.

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Left: The insulating layer of a cable showing mechanical damage. Right: A
simulation application for assessing cable health, called the “Cable Condition
Analysis Expert System”, with sample inputs and results.

4. Protect Wind Turbines from Lightning Strikes:-

 Wind turbines are susceptible to lightning strikes, which leads to costly

unplanned downtime unless they are properly protected. When designing
lightning protection for wind turbine blades, manufacturers know that
simple assumptions won’t do. It’s important to be able to predict how much
current will flow through the blade and exactly where it will flow, and this
requires deep insight into the material behavior and a way of testing the
large designs.
 At Lightning Technologies, an NTS company in the U.S., designers and
engineers use numerical modeling to overcome the challenge of physically
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testing 70-plus-meter-long blades. For accurate results, they combine
simulation with their own material expertise. For instance, the conductivity
of carbon (the material wind turbine blades are made of) varies in different
directions, and this behavior needs to be accurately represented in the
models for the protection to be designed properly. By using experimental
values for conductivity, the team at NTS can get realistic visualizations of
how the current will flow and then determine how to best protect the
carbon blade from burning away due to heating and/or arcing.

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Left: Wind turbines struck by lightning. Right: A model of a single wind turbine
blade, made of several carbon stacks, showing the current density in the blade.

5. Increase the Lifespan of Offshore Wind Farms:-

 Replacing failed transmissions in offshore wind turbines is both difficult

and expensive, but such upkeep is required when using mechanical
transmissions, where the continual contact leads to wear and tear. The team
at Sintex in Denmark has come up with a solution: noncontact magnetic
transmissions. When power is transferred via magnetic rather than
mechanical forces, the transmission system lasts longer and won’t need to
be replaced as often.
 To work, the magnetic couplings need to be tailor-made, so as part of the
design process, Sintex uses simulation to interchange shapes and materials
until the final component meets their customers’ needs. Physical
prototyping using magnets is prohibitive from both a financial and time
perspective, and because their designs involve multiple physics, COMSOL
Multiphysics is the team’s simulation software of choice. To allow
colleagues of all development stages as well as sales staff to run their own
system tests and design configurations, Sintex also builds custom
applications using the built-in Application Builder in COMSOL
Multiphysics.

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Left: An array of standard magnetic couplings. Right: A 3D model of a magnetic
coupling, used for analyzing the temperature distributions of the magnets and
magnetic flux densities in the iron.

6. Protect Satellite Systems from Electrical Arcing:-

 Satellite systems fail (partially or completely) if electrical arcing discharge

occurs, but it’s hard to predict when this might happen in systems designed
for extreme environments, such as space. Preventing destruction from
spontaneous electrical arcing requires first finding the critical region where
it might occur and then investigating potential triggers. It’s not feasible to
reproduce all possible operating conditions in space orbit with
experimental studies, but even with simulation there are challenges.
 Engineers at the Institute of High Current Electronics (IHCE) in Russia
determined that the only way to find self-sustained discharge regions is to
numerically simulate the discharge, but that it’s computationally very
expensive to do so. In the pursuit of a practical and accurate solution, the
team at IHCE used the Application Builder in COMSOL Multiphysics to
build a custom simulation application that autonomously partitions and
analyzes the device to find the most likely critical regions.

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Left: A circuit board that is used in satellite equipment. Right: A critical
parameter diagram showing pressure vs. emission for a critical region in the
model.

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 7. Develop Custom Capacitors Better and Faster:-
 Capacitor design requirements vary greatly depending on where they will
be used, so developers need to consider power specifications, operating
temperature ranges, and materials during the design process of custom
capacitors. Cornell Dubilier Electronics created high-fidelity multiphysics
models to virtually represent the capacitors and then wrapped their models
in easy-to-use interfaces (simulation applications). The applications are
then used by colleagues in other departments who need to test different
design configurations before selecting the best one for the task at hand.
 The underlying models developed by the simulation experts are accurate,
and the application interface is restricted so the end user only alters a few
design parameters that are meaningful to them. This means that colleagues
who do not know how to build multiphysics models can still benefit from
the results — without sending design specs back and forth to a simulation
expert.

Left: Aluminum electrolytic capacitors. Right: One of several simulation

applications built and used by Cornell Dubilier Electronics for analyzing
capacitors. This particular application is used for studying the effective series
inductance of a single-tab film capacitor.

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8. Evaluate the Structural Integrity of High-Performance Nuclear Fusion
Machines:-

 The MIT Plasma Science and Fusion Center (PSFC) is designing a

tokamak to be used as an R&D platform for testing the divertor concepts
required for a fusion reactor. The researchers call their proposed tokamak
the “Advanced Diverter eXperiment”, or ADX for short, and it would
operate at very high magnetic fields, thus increasing the plasma
performance to reactor levels. Their process for identifying and
understanding the science and technology that will make fusion energy
possible entails combining experiment, leading-edge theory, and numerical
simulation. One challenge they face is determining if the vacuum vessel
can survive worst-case plasma disruption events characterized by high heat
fluxes, magnetic fields, and Lorentz forces.
 Numerical modeling helped the team find answers to their design
questions. They created two models using COMSOL Multiphysics: one for
calculating the magnetic fields, eddy currents, and Lorentz forces resulting
from a plasma disruption; and another for predicting stress and
displacement in the vessel based on the calculations from their first model.

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Left: The proposed ADX tokamak design. Right: Simulation results of two
tokamak design iterations showing stress and displacement. The top row shows a
design with a single fixed boundary and the bottom row shows a design with an
additional boundary, where a support block is used as reinforcement.

9. Develop Custom High-Power Electrical Devices Better and at Lower

Cost:-

 Designing custom high-power electrical devices (such as transformers and

reactors) often means working with restrictions on size and materials.
When customers dictate the specs, each new product request is unique and
the design has to undergo rigorous testing before production. One
manufacturer of such products, BLOCK Transformatoren-Elektronik in
Germany, was looking to cut costs while also improving their services.
 Over many years, BLOCK had developed their own formulas for
describing magnetic materials and wanted simulation software that would
allow them to easily enter these formulas and use them in simulations.
They also wanted to utilize high-performance computing (HPC) to get
simulation results faster, and ultimately deliver products quicker to the
customer. COMSOL Multiphysics was the flexible simulation software
they were looking for.

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Left: A custom line reactor used for filtering out current spikes and reducing the
injection of harmonic currents into the power supply. Right: A 3D simulation of a
DC choke showing how it cools using airflow.

10. Protect Power Plants from Current Surges and Interruptions:-

 Developing generator circuit breakers for power plants requires coming up

with an extremely reliable design (brand new or an upgrade to an existing
design) and testing it to make sure it meets standards for commercial use.
The earthing switches that ground energized parts of the circuit breaker
system also need to be carefully designed and rigorously tested.
 For their earthing switches, ABB Group uses a tulip design, and they are
always looking to improve their designs. They needed to calculate the total
forces acting on the tulip contact, which involves coupled
electromechanical behavior. The team found that COMSOL Multiphysics
is a very nice tool to combine with empirical testing in their process of
analyzing and improving current designs.

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Left: The inside of a generator circuit breaker where tulip contacts are used for
the earthing switch. Right: A tulip contact model visualizing the current density
distribution. The symmetry of the tulip allowed the engineers to reduce the
computational cost to 1/8 th.
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References

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[3 https://www.directindustry.com/, "directindustry," [Online]. Available:

] https://www.directindustry.com/.

[4 https://www.essom.com/, "essom," [Online]. Available: https://www.essom.com/.

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[5 http://www.ayva.com/, "ayva," [Online]. Available: http://www.ayva.com/.

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[6 http://p-a-hilton.com/, "p-a-hilton," [Online]. Available: http://p-a-hilton.com/.

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END

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