10 Best Major Projects in Analysis for Mechanical Engineering Students

Introducrion

Table of Contents

1. Design & Thermal Analysis of Multi-Layer High-Pressure Vessel

Concept: Analyze multi-layer composite pressure vessels for optimized strength and thermal resistance using FEA and the Tsai-Wu failure criterion.

Explanation: This project models a composite pressure vessel (e.g., aluminum with fiber matrix) subjected to internal pressure and heat. Using ANSYS APDL and the Tsai-Wu failure theory, it evaluates ply failure and identifies the optimal number of layers to withstand operational stress.

Procedure:

• Model a symmetric multilayer composite vessel in ANSYS using shell elements.

• Apply boundary conditions and internal pressure loads.

• Use Tsai-Wu criteria to determine ply failure.

• Vary the number of layers (e.g., 7, 8) and analyze results.

• Evaluate structural integrity and compare to experimental results.

Applications:

• Aerospace fuel tanks

• Chemical storage

• High-pressure pipelines

Advantages:

• Lightweight and strong

• Tailored material properties

• Enhanced thermal resistance

Disadvantages:

• Complex manufacturing

• Delamination risk in composites

Components & Functions:

• Composite Layers (Al-Fiber): Structural strength

• FEA Tool (ANSYS/APDL): Simulation environment

• Failure Theory (Tsai-Wu): Criteria for ply failure

2. FEA Analysis of Camshaft

Concept: Evaluate dynamic behavior and stress distribution in a camshaft using FEA to optimize size and performance.

Explanation: This study analyzes camshaft deformation and stress under dynamic loading using ANSYS. The project assesses static and dynamic strain to ensure durability, using material properties like tensile strength for safety validation

Procedure:

• Import or model camshaft geometry in ANSYS.

• Apply real-time loading and constraints.

• Run static and dynamic analysis.

• Determine max stress and factor of safety.

• Validate the design based on strength criteria.

Applications:

• Automotive engines

• Power plants

• Rotary engines

Advantages:

• Accurate sizing

• Predicts fatigue areas

• Enhances durability

Disadvantages:

• Requires precise loading data

• Software expertise needed

Components & Functions:

• Camshaft Model: Geometry under study

• FEA Software: Analysis platform

• Material Data: Used for safety checks

3. FEA Analysis of Composite Leaf Spring

Concept: Replace traditional steel leaf springs with lighter, corrosion-resistant composite springs in vehicles.

Explanation: The project compares traditional steel springs to composite alternatives through 3D modeling and stress analysis in ANSYS. It aims to reduce vehicle weight and improve performance.

Procedure:

• Model single-leaf composite spring in CAD.

• Assign material properties (e.g., glass fiber).

• Apply loading conditions simulating vehicle weight.

• Analyze deformation, stress, and weight.

• Compare performance to steel springs.

Applications:

• Automotive suspension systems

• Light commercial vehicles

Advantages:

• 67% weight reduction

• Corrosion-resistant

• Cost-effective in bulk

Disadvantages:

• Brittle failure potential

• Costlier raw materials

Components & Functions:

• Composite Spring (Glass/Carbon Fiber): Load support

• ANSYS: FEA simulation

• Fixture Points: Boundary condition setup

4. FEA Analysis of Disc Brake

Concept: Analyze the braking efficiency, stress, and heat dissipation of disc brakes using FEA.

Explanation: The study uses ANSYS to evaluate heat buildup and structural wear in disc brakes under load. Material choice is key, with grey cast iron emerging as the best option for thermal and stress resistance.

Procedure:

• Model disc and caliper in 3D CAD.

• Apply braking force and frictional heat load.

• Analyze thermal expansion and stress zones.

• Compare different materials (e.g., cast iron, steel).

• Recommend optimal design and material.

Applications:

• Automobiles

• Bikes and scooters

• Light rail transport

Advantages:

• Enhances brake life

• Prevents thermal failure

• Identifies critical stress zones

Disadvantages:

• Thermal modeling complexity

• Limited to simulated conditions

Components & Functions:

• Disc Rotor: Braking surface

• Caliper: Applies clamping force

• Material Input: Defines thermal capacity

5. FEA of Centrifugal Pump Impeller

Concept: Improve the strength and durability of centrifugal pump impellers using stress and modal analysis.

Explanation: The impeller’s performance is analyzed for different materials like MS and SS. ANSYS is used to study deflection, stress, and safety factors under rotational speed and fluid pressure.

Procedure:

• Model impeller with blade geometry.

• Apply centrifugal and fluid pressure loads.

• Perform static and modal analysis.

• Compare results for MS and SS materials.

• Determine optimal design for reliability.

Applications:

• Irrigation

• Industrial pumping

• Chemical processing

Advantages:

• Low stress and deformation

• Material optimization

• Safer design margins

Disadvantages:

• Assumes ideal flow

• SS is costlier than MS

Components & Functions:

• Impeller Blades: Pressure generation

• FEA Tool: Simulates forces

• Material Property Input: Strength & Density

6. Spur Gear Stress Analysis

Concept: Analyze stress in spur gears used in a footstep power generator to determine gear strength and safety.

Explanation: A 3D spur gear is modeled in ANSYS, with torque applied to determine stress concentration. Results validate the material and size choices.

Procedure:

• Design spur gear in CAD.

• Import to ANSYS and apply 50 Nm torque.

• Perform static structural analysis.

• Observe stress points and FOS.

• Recommend gear material (MS).

Applications:

• Mechanical power generation

• Robotics

• Small transmission units

Advantages:

• Validates safety

• Prevents premature gear failure

• Ensures material reliability

Disadvantages:

• Single-load condition tested

• Not applicable for bevel/helical gears

Components & Functions:

• Spur Gear: Rotational transfer

• Torque Load: Input energy

• Material (MS): Provides strength

7. Structural Analysis of Angle Plate

Concept: Evaluate the structural safety of angle plates used to support long shafts.

Explanation: The project uses FEA to study the stress concentration and deformation of angle plates, especially around bolt holes and free ends, ensuring safe design.

Procedure:

• Model the angle plate with the shaft in CAD.

• Apply static shaft weight and constraints.

• Perform FEA simulation.

• Identify max stress zones.

• Suggest structural enhancements.

Applications:

• CNC setups

• Shaft support systems

• Machine fixtures

Advantages:

• Identifies weak points

• Aids in lightweight design

• Improves bolt placement

Disadvantages:

• Limited to static load

• Ignored dynamic loads

Components & Functions:

• Angle Plate: Load carrier

• Bolt Holes: High-stress region

• ANSYS: Structural analysis tool

8. Structural and Thermal Analysis of Steam Turbine Blade

Concept: Improve the fatigue life of steam turbine blades by analyzing stress and heat effects.

Explanation: Analyzes rotor blade behavior under centrifugal force and thermal stress. Adds axial holes for stress reduction and evaluates their effect on blade fatigue life.

Procedure:

• Design rotor blade with varying axial holes.

• Apply thermal and rotational loading in ANSYS.

• Measure stress, deformation, and fatigue cycles.

• Compare designs (2mm vs. 3mm vs. 4mm holes).

• Recommend optimal blade configuration.

Applications:

• Power plants

• Industrial turbines

Advantages:

• Extends blade life

• Optimizes heat dissipation

• Improves fatigue resistance

Disadvantages:

• Adds manufacturing complexity

• Hole position critical

Components & Functions:

• Rotor Blade: Energy conversion

• Axial Holes: Stress relief

• ANSYS: Combined thermal-structural solver

9. Thermal Analysis of Heat Pipe

Concept: Use the Taguchi method and FEA to optimize heat pipe performance parameters.

Explanation: The project applies the design of experiments (DOE) using Taguchi to assess how heat input, tilt angle, and flow rate affect performance. ANSYS models are used to validate findings.

Procedure:

• Create a 3D model of a heat pipe.

• Simulate heat transfer with variable parameters.

• Apply DOE using the Taguchi method.

• Compare thermal resistance and temperature drop.

• Finalize optimal configuration.

Applications:

• Laptops and PCs

• Aerospace cooling

• Solar collectors

Advantages:

• Efficient parameter tuning

• Minimizes test iterations

• Validates design choices

Disadvantages:

• Assumes ideal conditions

• Limited to test ranges

Components & Functions:

• Heat Pipe Model: Geometry for Testing

• DOE (Taguchi): Optimization tool

• Thermal Simulation: Predicts performance

10. Thermal Analysis of Cylinder Head Gasket

Concept: Improve sealing performance and reduce heat loss in engine gaskets using thermal FEA.

Explanation: Designs and analyzes a cylinder head gasket for efficient sealing under combustion loads. ANSYS evaluates thermal and mechanical stress zones.

Procedure:

• Design a gasket in PROE based on the cylinder head specs.

• Import to ANSYS and apply combustion temperature and pressure.

• Conduct thermal and structural simulations.

• Identify failure-prone regions.

• Recommend material and design changes.

Applications:

• Internal combustion engines

• Marine engines

• High-performance vehicles

Advantages:

• Prevents gas leakage

• Increases engine efficiency

• Enhances gasket lifespan

Disadvantages:

• Requires high-fidelity modeling

• Sensitive to mounting precision

Components & Functions:

• Gasket Geometry: Sealing element

• ANSYS/PROE: Design + simulation combo

• Thermal Input: Simulates heat flow from combustion