College of Engineering

EGA324 Mechanical Engineering

Practice

Session 2018/19

Course Notes
Note: Up-to-date information on this module should always be on Blackboard and announcements
will be sent to your student email address.
Assignments must be submitted electronically through Turnitin. The assignment will be marked
within 2-3 weeks from submission, as per University guidelines.
Dr S Jeffs (Module Coordinator)
Office: ISM 0.17
Office hours: Mondays 11-12
E-mail: [email protected]

EGA324 Course Notes 1 2018-19

 Contents
Module Overview 3
Experiment Requirements 8
Experiment 1 – Aerofoil In Wind Tunnel ....................................................................................................... 8
Experiment 2 – Bolted Joint Experiment ...................................................................................................... 11
Experiment 3 – Stress Concentrations ........................................................................................................... 13

Assignments 15
C1 – Aerofoil experiment (30%) ................................................................................................................... 15
C2 – Boundary Layer & Stress Concentrations (30%) .................................................................................. 15
C3 – Comparing Modelling to Experimental Data (50%) ............................................................................. 15
Tips on Reporting Computational Aspects for C3 ........................................................................................ 15

Technical Report Writing Guidelines 20

Summary of Rubric/Marking Schemes 23
C1 & C2 Assignment .................................................................................................................................... 23
C3 Assignment .............................................................................................................................................. 24

EGA324 Course Notes 2 2018-19

Module Overview

Aims of the Module

The course builds on the knowledge and experience developed by the students in experimental
studies during Level 2.
A number of advanced scientific experiments will be undertaken.
In addition, students will carry out a number of computational modelling benchmarks in order to
develop their ability to create appropriate models, interpret the predictions and compare them with
alternative solutions.
For this module, there are 3 experiments will be carried out and written up across 3 assignments
(C1, C2 and C3) and a series of online blackboard tests. You will undertake experiments in pre-
allocated laboratory sessions that you will do in the group allocated. Each of the assignments
consists of reports, which you will do individually (NOT AS A GROUP).
The experiments you will undertake are:
• EX01) Flow Over an Aerofoil (described on page 8)
• EX02) Bolted Joint (described on page 11)
• EX03) Stress Concentration Experiment (described on page 13)

In addition to the experiments, you will also be doing an ANSYS training course which will progress in
three stages (beginner, intermediate and advanced).

Learning Outcomes

On completion of this module, students will be able to demonstrate:

• LO1 – Advanced Technical Reporting - Undertake scientific experiments and report the outcome
in a well written technical report.
• LO2 – Experimental Practise - Advanced knowledge and critical understanding of a wide range
of experimental techniques, designing specific experimental test programmes to meet open-end
objectives. An ability to select and implement suitable measuring equipment and develop
appropriate advanced experimental procedures to meet the experimental objectives.
• LO3 – Computational Validation - Advanced knowledge and critical understanding of
computational modelling techniques in order to achieve accurate predictions. An ability to
critically appraise the accuracy of numerical predictions, by comparison with alternative
solutions

Transferable Skills

On completion of this module, the student will be able to demonstrate:

• Independent research and critical thinking skills
• Problem solving, time management and group working skills
• Improved skills in report writing in a clear and concise form.

Syllabus

Experiments will be completed on:

• Wind Tunnel (Fluid dynamics)

EGA324 Course Notes 3 2018-19

 • Stress concentration features (Stress analysis)
• Stresses in bolted joints (Multi-assembly loading analysis)
• Modelling benchmarks (Fluid, Stress)
Each of these will have supporting lectures.
Lab attendance is compulsory, you will not be allowed to use a colleague’s data.

Timetable 2018-19

1-hour lecture per week every Monday 9-10 in B001 (Engineering Central)
Experimental and ANSYS PC labs run simultaneously, each week you will either be completing an
experiment or an ANSYS tutorial session as per the following schedule and timings:
Term week 1 2 3 4 5 6 7 8 9 10 11
Week commencing 04-Feb-19 11-Feb-19 18-Feb-19 25-Feb-19 04-Mar-19 11-Mar-19 18-Mar-19 25-Mar-19 01-Apr-19 08-Apr-19 06-May-19
University week 20 21 22 23 24 25 26 27 28 29 33
LECTURE EC/B001 Monday 9-10 All
Wind tunnel EC/B012
Exp 1 - Aerofoil (Mon) Groups 1-8 Groups 17-24 * *
Exp 1 - Aerofoil (Tues) Groups 9-16 Groups 25-32 * *
ANSYS Beginner
CF104 - (Mon) Groups 25-32 Groups 9-16
EC/C101 - (Tues) Groups 17-24 Groups 1-8
Metallography EE/A015-019
Exp 2 - Bolted Joint (Tues) Groups 1-8 Groups 17-24
Exp 2 - Bolted Joint (Thurs) Groups 9-16 Groups 25-32
ANSYS Intermediate
EC/C101 (Tues) Groups 25-32 Groups 9-16
The College/RM 25 (Thurs) Groups 17-24 Groups 1-8
Metallography EE/A015-019
Exp 3 - Stress Concentrations (Tue) Groups 1-8 Groups 17-24 *
Exp 3 - Stress Concentrations (Thu) Groups 9-16 Groups 25-32 *
ANSYS Advanced
EC/C101 (Tues) Groups 25-32 Groups 9-16
The College/RM 25 (Thurs) Groups 17-24 Groups 1-8
PC Labs for EGA324 C3
EC/C101 - (Tues) Groups 1-8 Groups 17-24 Groups 1-8 Groups 17-24
The College/RM 25 (Thurs) Groups 9-16 Groups 25-32 Groups 9-16 Groups 25-32

Experiment Lab Timings:

ANSYS PC Lab Timings:

ANSYS BEGINNER ANSYS INTERMEDIATE ANSYS ADVANCED
Monday 4th Feb Tuesday 5th Feb Tuesday 19th Feb Thursday 21st Feb Tuesday 5th Mar Thursday 7th Mar
CF104 EC/C101 EC/C101 The College/RM 25 EC/C101 The College/RM 25
12:00 16:00 Groups 25-32 09:00 13:00 Groups 17-24 09:00 13:00 Groups 25-32 09:00 13:00 Groups 17-24 09:00 13:00 Groups 25-32 09:00 13:00 Groups 17-24

Monday 11th Feb Tuesday 12th Feb Tuesday 26th Feb Thursday 28th Feb Tuesday 12th Mar Thursday 14th Mar
CF104 EC/C101 EC/C101 The College/RM 25 EC/C101 The College/RM 25
12:00 16:00 Groups 9-16 09:00 13:00 Groups 1-8 09:00 13:00 Groups 9-16 09:00 13:00 Groups 1-8 09:00 13:00 Groups 9-16 09:00 13:00 Groups 1-8

Grouping for Experiments

The students in this module are placed in groups of 5/6 to undertake the experiments for the
purpose of collecting the data. However, it should be stressed that this is NOT a group assignment, it
is an individual assignment.
The student grouping can be found on blackboard in the module “Timetable & Groups” section.
Attending the experimental laboratory session is mandatory. All groups should be there at least 10
minutes before start.
Please do not be late for experiments. If a student is more than 15 minutes late for the experiment,
they will have missed the academic brief, the health and safety induction and the operational
EGA324 Course Notes 4 2018-19
instructions on the equipment. This might delay the start of the experiment and may have a negative
impact on the other students in the group. You will be asked to see the coordinator and repeated
tardiness will be penalised.
Students with extenuating circumstances should apply for EC using the usual college procedures,
however, it is important that at the earliest convenient moment you contact the module coordinator
so that an alternative laboratory session can be organised.
• You are expected to have watched the online experimental brief which includes health and
safety and have passed the test on blackboard prior to attending the lab – best done on the
Monday of each week of your experiment. If you do not do this you may not be allowed to
attend the lab, and certainly will not be submit the lab report.
• Appropriate clothing is critical for the labs (no flip-flops or sandals, arms and legs covered) – the
demonstrator has the authority to stop inappropriately dressed students from undertaking the
experiment.
• No food or drink is allowed in the laboratory.
• Data from experiments will be emailed to each group at the end of the lab session.
• If you are late you will be asked to report the coordinator and may be penalised.
• The lecturer/demonstrator will run over the practical side of the experiment and enforce H&S
aspects.

Staff Contacts, Laboratory Locations and Office Hours

The coordinator for this module is Dr Spencer Jeffs, who is also the lead academic for the Stress
Concentration experiment. Dr Nick Lavery is the lead academic for the Wind Tunnel Aerofoil
experiment, and Dr Hadi Madinei is the lead academic for the Bolted Joint. It is the lead academics
role to provide insight into the physics in the experiment, as well as to explain to you what is
required from the experiment and assignment write-up, in order to maximise your marks. The lead
academic will be present for approximately the first 15 minutes of each experiment.
Each experiment has an associated technician (Jeremy Davies) and a student demonstrator who will
be present for the duration of the experiment. The technician will lead you through the health and
safety requirements of the experiment and trouble shoot any equipment problems. The student
demonstrator will be there to assist you with any questions regarding the experiment, operation and
to some extent on the physics of the experiment.
The academic office locations and office hours for this module are posted on blackboard under
“Staff Contacts”.
Experiments Title Lecturer Location Demonstrator Technician
PC Labs Modelling Dr Nick Lavery As per timetable Jordan Rosser -
(ANSYS) (Advanced) allocation (636595)
Dr Spencer Jeffs
Sam Minshell
(Intermediate)
(442714)
Dr Hadi Madinei
(Beginner)
Exp 1 Flow over an Dr Nick Lavery Eng Central - Wind Connor Boyle Mr Jeremy
Aerofoil Tunnel Laboratory (B012) (797869) Davies
Exp 2 Bolted Joints Dr Hadi Madinei Eng East - Metallography Steve Jordan -
Lab Materials (530573)
(A015,A016,A019)
Exp 3 Stress Dr Spencer Jeffs Eng East - Metallography Steve Jordan -
Concentrations Lab Materials (530573)
(A015,A016,A019)

EGA324 Course Notes 5 2018-19

Assessment Summary

This module is a 10-credit module. It has 3 components in the form of written assignments:
• C1: marking scheme assessment UG weighting 30% (February)
• C2: marking scheme assessment UG weighting 30% (March)
• C3: marking scheme assessment UG weighting 40% (April)
In addition to these continuously assessment component there are a series of Pass/Fail online
tests (blackboard):
• Prior to each experiment all students must have undertaken the mandatory experiment
preparatory test on blackboard with a P/F criteria. Watch the online video and answer a
number of questions on health and safety and experiment planning for each experiment.
These are best done on the Monday before the experiment that week. These tests must be
passed to submit assignments C1 and C2.
• There will be a single short online test with a P/F criteria on the Bolted Joint Experiment
(EXP02). This test must be completed to submit assignment C3.
• There will be an online test with a P/F criteria based on the ANSYS tutorials (Beginner,
Intermediate) - this must be passed to submit assignment C3.
Each of the C1-C3 assignments will take the following form:
• C1 (30%): An 8-page formal report on experiment 1 (Flow over an Aerofoil in the subsonic
wind tunnel) undertaken in weeks 1 and 2. This assignment will address the learning
objective LO1 & LO2.
• C2 (30%): An 8-page formal report on experiment 3 (Stress Concentrations) undertaken in
weeks 5 and 6. This assignment will address the learning objectives LO1 & LO2.
• C3 (40%): This report will be a 10 page report comparing experiments 1 & 3 with
computational model results, and will be due at the end of week 10. This assignment will
cover learning objective (LO3).
General information on how to structure and write a good report can be found at the end of this
document and on Blackboard. You will also be given an overview of what is expected from the
reports during the preliminary lectures, as well as a refresher on key areas of fluid dynamics, stress
analysis and computational modelling.
Note: The report section of the module is scrutinised for any unfair practice and plagiarism, and
any infringement is taken VERY seriously, as per University regulations.
Under the same guidelines, do not cut and paste from the Course Notes, and when asked to put
sections (e.g. Summary/Aims) in your own words, do so. Marks will not be given for sections which
simply copy or repeat words or images from the Course notes.
All the experiments have a dedicated health and safety induction and these should be taken
seriously, followed during the laboratory session, and need to be briefly summarised in your
technical report. A strict requirement for the laboratory is that suitable footwear and full-length
trousers and shirts should be worn, in addition to any specific PPE requirements (goggles, ear
protection etc.) for any given experiment.

EGA324 Course Notes 6 2018-19

Assignment Deadlines, Submission and Feedback

Assignments will be submitted electronically through Turnitin, via the “Assessment & Feedback”
page.
Specific dates for each component are given below:
• C1 (30%): Deadlines are 4pm:
o Groups 1-8 14th Feb
o Group 9-16 15th Feb
o Groups 17-24 21st Feb
o Groups 25-32 22nd Feb

• C2 (30%): Deadlines are 4pm:

o Groups 1-8 15th March
o Group 9-16 15th March
o Groups 17-24 22nd March
o Groups 25-32 22nd March

• C3 (40%): Deadline is 4pm on 12th April 2019 for all students.

The assignment will be graded within 2-3 weeks from submission, as per University guidelines.
Feedback will be attached to the Turnitin submission.
Marking rubrics can be found at the end of this document.

EGA324 Course Notes 7 2018-19

Experiment Requirements
The experimental requirements are defined here for the three experiments you will undertake.
These will form the basis of your write-up in assignments C1 and C2.

Experiment 1 – Aerofoil In Wind Tunnel

Lecturer: Dr Nick Lavery ([email protected])
Technician: Mr Jeremy Davies ([email protected])
Laboratory: Eng Central - Wind Tunnel Laboratory (B012)
Practical day/time: Weeks 1&2 – Monday 12-5 & Tuesday 9-2
Module Office Hours (location/day/time): Engineering East/A203, Wednesdays 13:00-14:00

OBJECTIVES

The main aim of this assignment is to obtain experimental pressure distributions, as well as lift and
drag coefficients, for a NACA0012 aerofoil at a range of angles of attack. The second part of the
assignment is to use validate the experimental data through the use of computational fluid
dynamics.

EQUIPMENT AND METHODOLOGY

The following is available: For this experiment you will be using the AF100 Subsonic wind tunnel
fitted with the 150mm chord NACA0012 airfoil. This foil has pressure taps and the machine is set-up
to display both pressure at the tapped locations, as well as a recording lift and drag forces.
For the report, give a brief describe how the wind tunnel works and include a picture schematics of
the rig including the instrument panel and how the data is collected.
In the appropriate sections of the report, you will need to describe the experimental methodology of
the test.
Answer the following questions:
• Why is the fan positioned at the outlet and not the inlet?
• Why is there a grid at the entrance of the wind tunnel?
• Why is the entrance designed much wider than the middle section?

RESULTS/DISCUSSION REQUIRED

During the experiment, you will have experimented with different flow rates in the wind-tunnel (e.g.
U=10, 20, 30 m/s), and changed the angle of attack of the aerofoil between 0° and 18°, in 2° interval
stages. The data will be saved and emailed to you by the student demonstrator at the end of the
practical session. For each of the velocities tested (U=10, 20 and 30 m/s), calculate the
corresponding Mach and Reynolds number.
From the experimental data, enter the pressure tap values into the excel sheet provided completing
a table such as the one below (also provided as a template excel spreadsheet on blackboard) for at
least four angles of attack (α=2°, α =8°, α =14°, α =17°).
Include one of these tables (α =8°) into the report at a velocity of your choice, and number and label
as Table 1. VERY IMPORTANT – CHECK TAPPING NUMBERS & LOCATIONS

EGA324 Course Notes 8 2018-19

Table 1 – Pressure coefficient for NACA0012 aerofoil at α =8° and U=21.9 m/s

Wall pressure upstream, PW = 0.29 kPa 290 Pa

Angle of attack (AoA), α= degrees
Ambient temperature,
Ta = 21 °C 294.15 °K
Ambient pressure, Pa = 1021 mbar 102.1 kPa
Air density = 1.209414 kg/m^3
Wind tunnel velocity = 21.89911 m/s
Distance Local
from Pressure Relative
Tapping Number leading x/c display, Static Cp
edge x PT (kPa) Pressure
(mm) (kPa)
START 0 0.000
1 0.76 0.005
3 3.81 0.025
5 11.43 0.076
7 19.05 0.127
9 38 0.253
11 62 0.413
Upper surface

13 80.77 0.538
15 101.35 0.676
17 121.92 0.813
19 137.16 0.914
END 150 1.000
START 0 0.000
2 1.52 0.010
4 7.62 0.051
6 15.24 0.102
8 22.86 0.152
10 41.15 0.274
12 59.44 0.396
Lower surface

14 77.73 0.518
16 96.02 0.640
18 114.3 0.762
20 129.54 0.864
END 150 1.000

On a single graph (Figure 1), plot 3 pressure distributions over the aerofoil prior to and after the stall
angle (e.g. at α =8°, α =14° and α =17°) for the highest of your wind tunnel velocities (e.g. U=30m/s),
using the distance from the leading edge (in mm) as the x axis, and the pressure on the vertical axis
(in kPa). Use different colour curves for the upper and lower surfaces, clearly identifying which one is
which.
Lift and drag forces are readily available from the exported data, and the first thing to do is create 3
plots (Figures 2, 3 & 4) of lift and drag forces as a function of the AoA, for each of the velocities
tested. Remember that the data is recorded at a number of sampling times (10) for each AoA, and
you can take and average of the sample data set, with an associated standard deviation. Make sure
you use the correct units and labels for the axes.
EGA324 Course Notes 9 2018-19
For U=30m/s, convert the lift force into a lift coefficient, and plot as a function of AoA on a separate
graph, Figure 5. Obtain data at a similar Reynolds number from a previous source (e.g. Gregory et al.
[1]) and include this on your plot. State the equation for the lift coefficient and the values which you
have used to calculate the coefficients.
For the discussion:
• Are there any appreciable fluctuations in either the recorded pressures or velocities?
• Is there any reason to doubt the accuracy of the measured lift and forces?
• Can you include a measure of error bars on your experimental data?
• Describe the shape of the pressure distributions over the aerofoil using Bernoulli’s equation.
• Indicate the stall angle and describe how you determined that value.
• Explain your results – what happens to the flow over the aerofoil as it approaches and goes
beyond the stall angle? How are the pressure and velocity connected along a streamline?
• Were you able to obtain previous data for comparison at a similar Reynolds number and for
the same foil (NACA0012). If not, how do your results compare to the measured results in
the reference given to you (Gregory et al.[1])?

COMMENTS

Think carefully about what you are trying to achieve before starting – plan the test programme with
your group – take photographs of the equipment if you can.
Watch the Experiment video and answer the quiz test on Blackboard as this is requirement to be
able to attend the laboratory.
Take particular note of the health and safety description prior to experimentation, and follow these
at all times in the laboratory.
A template for the report is available on Blackboard (EGA324 Assignment C1 -surname-studentID-
000000 (17-18).doc).
At the end of the experiment your group will be emailed the data by the student demonstrator.

REFERENCES

[1] N. Gregory and C. L. O’Reilly , “Low Speed Aerodynamic Characteristics of NACA 0012 Aerofoil
Section, including the Effects of Upper-Surface Roughness Simulating Hoar Frost” Aeronautical
Research Council, Report No. 3726, January 1970.

EGA324 Course Notes 10 2018-19

Experiment 2 – Bolted Joint Experiment
Lecturer: Dr Hadi Madinei ([email protected])
Technician: Mr Jeremy Davies ([email protected])
Demonstrator:
Laboratory: Eng East/A015,A016,A019/Metallography Lab Materials
Practical day/time: Weeks 3&4 – Tuesday & Thursday 9-2
Module Office Hours (location/day/time): Engineering East/B214, Tuesdays 15:00-16:00

OBJECTIVES

This experiment is to investigate the strength of bolted connections in steel plate. It is an open
ended experiment and the group are expected to plan their own experimental programme.
The aim of the experiment is to investigate the effects of moving the location of the hole through
the plate, specifically to:
• Investigate the relationship between bolt position and failure mode of a bolted joint.
• Investigate the relationship between the distance from the end of the sample and the ultimate
strength
• Understand the failure mechanisms during failure and how they change with bolt position.
• Explore the stiffness of bolted joints.

EQUIPMENT AND METHODOLOGY

The following is available: Dartec universal testing machine and sample manufacturing facility.
Describe how this works and include picture schematics of the rig. Describe the experimental
methodology. Show that there are sufficient repeated tests to show consistency of results and to
minimise experimental error.
During the time available you will need to plan and carry out all of your tests. You have exclusive
access to the test machine and technician. You should make notes during the experiment in your log
book.

RESULTS/DISCUSSION REQUIRED

Results
• Plot a typical force/displacement graph by including here an appropriate graph (correctly
labelled).
• Through a short description, show that you understand the various sections of the graph.
• Develop a comprehensive graph (correctly labelled) that shows all the data (scatter points plus
average line). You should plot your main variable (bolt spacing) on the x axis and peak strength
on the y axis. Plot one point per test sample (no lines). Plot an average line (do not tick the
smoothed line option in excel). This graph should summarise ALL your results visually.

Discussion
• Discuss the relationship between the distance from the end of the sample and the ultimate
strength
• Discuss the failure mechanisms for a bolt close to the end of the sample.

EGA324 Course Notes 11 2018-19

• Understand the failure mechanisms for a bolt a distance from the end of the sample. Where is
the transition point?

COMMENTS

Think carefully about what you are trying to achieve before starting – plan the test programme with
your group – take photographs of the equipment if you can.
Watch the Experiment video and answer the quiz test on Blackboard as this is requirement to be
able to attend the laboratory.
Take particular note of the health and safety description prior to experimentation, and follow these
at all times in the laboratory.
At the end of the experiment your group will be emailed the data by the student demonstrator.

EGA324 Course Notes 12 2018-19

Experiment 3 – Stress Concentrations
Lecturer: Dr Spencer Jeffs ([email protected])
Technician: Mr Jeremy Davies ([email protected])
Laboratory: Eng East/A015,A016,A019/Metallography Lab Materials
Practical day/time: Weeks 5&6 – Tuesday/Thursday 9-2
Module Office Hours (location/day/time): ISM/0.17, Mondays 11:00-12:00

OBJECTIVES

The aim of this experimental investigation is to quantify the effects of introducing a stress
concentration feature to a component or structure. A number of mild steel tensile specimens are
provided with and without stress raisers and the tensile load characteristics of these specimens are
to be compared and contrasted.

EQUIPMENT AND METHODOLOGY

The following is available:

Hounsfield 25 kN electrically-operated tensile test machine
Extensometer – why is the use of extensometry important?
12 mild steel tensile test components (1 mm thick)
Sample A) 2 plain
Sample B) 2 with 2 mm central hole
Sample C) 2 with 5 mm central hole
Sample D) 2 with single-sided semi-circular R2.5 mm notch
Sample E) 2 with double-sided semi-circular R2.5 mm notch

RESULTS/DISCUSSION REQUIRED

Yield load (N) Ultimate Tensile Load (N)

Sample ID Specimen1 Specimen1 Specimen1 Specimen1
A Plain
B 2mm central hole
C 5mm central hole
D 8mm central hole
E Single-sided notch
F Double-sided notch
Table 1 - Summary of Results
• A summary of all the yield and ultimate tensile loads as required in Table 1.
• Insert a plot of the load-displacement curves for all the 5 types of test components
• How does the size of the hole affect the tensile characteristics of the components and why?
• How does the number of notches affect the tensile characteristics and why?

EGA324 Course Notes 13 2018-19

• How do the tensile characteristics for a 5 mm hole compare with those for two R2.5 mm notches
and why?
• Rank the five stress raisers in terms of their impact on the components’ behavior under load.
• Compare and contrast the degree and form of the deformation (strain) at failure for the
different stress raisers and how do they compared with the plain specimen?
• How do the shapes of the fracture surfaces compare and why might they be different?
• Comment on the repeatability of the tests and how could accuracy be improved?
• Use the Neuber’s rule as described in the lecture on stress concentrations, with the
experimentally derived stress-strain curves to get stress concentration factors for each of the
stress raisers. Compare these with the empirical SCFs for holes and notches. How do they
compare?

COMMENTS

Watch the Experiment video and answer the quiz test on Blackboard as this is requirement to be
able to attend the laboratory.
Take particular note of the health and safety description prior to experimentation, and follow these
at all times in the laboratory.
Think carefully about what you are trying to achieve before starting – take photographs of the
equipment if you can.
Refer to Level 2 Stress Analysis (EG-262) notes as a reminder.
This experiment will reported in assignment C2 - a template for the report is available on Blackboard
(EGA324 Assignment C2-surname-studentID-000000.doc).
At the end of the experiment your group will be emailed the data by the student demonstrator.

REFERENCES

[1] W. C. Young and R. G. Budynas, Roark’s Formulas for Stress and Strain, 7th ed. New York:
McGraw-Hill, 2002.

[2] E. J. Hearn, Mechanics of Materials 2, 3rd ed. Oxford: Butterworth-Heinemann, 1997.

EGA324 Course Notes 14 2018-19

Assignments
This module is worth 10 credits and there are 3 assignments C1 worth 30%, C2 worth 30% and C3
worth 40%. All assignments C1, C2 and C3 are to be submitted via Turnitin on blackboard. See
section at the end of these notes on how to write a technical report.
For each assignment the report template & guidelines are given on Blackboard under “Module
Content” along with the notes provided in this document and the accompanying lectures slides.

C1 – Aerofoil Experiment (30%)

This assignment consists of an 8-page formal report on experiment 1 (Flow over an aerofoil in the
subsonic wind tunnel) undertaken in weeks 1 and 2. This assignment will address the learning
objective LO1 & LO2.

C2 – Stress Concentrations Experiment (30%)

An 8-page formal report on experiment 3 (Stress Concentrations) undertaken in weeks 5 and 6. This
assignment will address the learning objectives LO1 & LO2.

C3 – Comparing Modelling to Experimental Data (40%)

This report will be a 10-page report comparing experiments 1 & 3 with computational model results
(5 pages per experiment) and will be due at the end of week 10. This assignment will cover learning
objective (LO3).
All students will undertake the Modelling tutorials PC laboratory sessions over the first 6 weeks of
term, which will progress from Beginner levels through to Advanced levels. In the PC labs, you will
learn the basics of using ANSYS-Fluent and ANSYS-Structural, as applied to specific examples which
are linked to the experiments. A key aspect of this module is the ability to undertake computational
modelling as a guide to the experimental work, and most critically to be able to interpret and
validate the computational results.

Tips on Reporting Computational Aspects for C3

COMPUTATIONAL ASPECTS OF AEROFOIL EXPERIMENT

Software/Module: ANSYS Fluent with mesh/geometry generation in Workbench Designer.

Tutorial 7 (ANSYS Advanced):
In the tutorial sessions you will have been shown how to:
• Create an aerofoil profile, import it into ANSYS designer, create a 2D surface-based
geometry, and use ANSYS meshing to create a mesh for ANSYS Fluent.
• Create workbench parameters in ANSYS designer for the angle of attack, and also for the
FLUENT INLET velocity.

EGA324 Course Notes 15 2018-19

 • Mesh this geometry, how to refine the mesh and create named sections. The named
sections will be used to set the boundary conditions in FLUENT. You will have been shown
how to access and modify input boundary conditions such as inlet velocity.
• Select air as the flow medium asses fluid/gas flow properties such as viscosity and density.
• Run the analysis with a k-ε turbulence model
So by the time you are doing assignment C3, you will have a working FLUENT model, which you will
use to compare to your experimental data. In the demonstration session you will not the models
through to completion, but you will be shown how to use ANSYS CFD-post to look at your results.
The tutorial on on how to run the FLUENT models can be found on page Error! Bookmark not
defined.:
1) Single Analysis. For the NACA0012 aerofoil at an angle of attack of α=8° and a wind tunnel
velocity of 20m/s, add the following plots to your report (make sure plots include a legend
and number/values are legible)
a) Aerofoil profile indicating the chord and the camber
b) Geometry indicating length and height of test section and AoA.
c) Mesh used for analysis indicating refinement level and number of elements
d) Geometry showing highlighted boundary conditions
e) Contours of velocity (include the legend)
f) Contours of pressure (include the legend)
g) Streamlines emanating from INLET
h) Velocity vectors (zoom in to the aerofoil to show vectors close to wall)
i) Graph of pressure over aerofoil, clearly indicating the section of graph
corresponding to the upper and lower sections of the aerofoil
j) What is the Reynolds number based on the INLET velocity and the aerofoil chord
length?
k) What is the Mach number?
l) What are the lift and drag forces for this AoA?
m) What are the lift and drag coefficients for this AoA?
For the validation, use either the 2D or the 3D models developed in ANSYS Tutorial 8.
1) Mesh sensitivity (Coarse, Medium, Fine) – For the same AoA and velocity studied in the first
section, what effect does the refinement have on convergence? What effect does refining
the mesh have on calculated lift and drag forces?

2) Boundary Condition sensitivity. Run the NACA0012 model for angles of attack ranging from
α=0° to α=17°, with the three INLET velocities you used in the experiment (e.g. U=10, 20 and
30m/s). Using the data in the parameter set, copy and paste into excel the columns B (AoA),
C (Inlet Velocity), D (x force) and E (y force). For each AoA calculate the lift and drag
coefficients, as well as the lift to drag ratio. Plot three graphs with AoA on the x-axis versus,
the lift coefficient, the drag coefficient and the lift to drag ratio. Include on each graph a
separate series for each of the velocities.

3) At what angle does the aerofoil stall? At which angle is the highest lift to drag ratio? How
does the experimental data compare to the computational data?

4) How does your data compare to the experimental data from Gregory et al,[1]? Be sure to
state which figure you are comparing data to, and also the relevant Reynolds number. Are
there any other references you could use?

EGA324 Course Notes 16 2018-19

COMPUTATIONAL ASPECTS OF STRESS CONCENTRATION EXPERIMENT

Software/Module: Transient Structural Stress Analysis in ANSYS

Tutorial 9 (ANSYS Advanced):
The analysis in this section relates to the Stress Concentration experiment (E3) you will have
undertaken in the laboratory earlier in the term. Specifically during the tutorial sessions you will
undertake a non-linear finite element stress analysis using ANSYS of uniaxial test bars (dog bones)
with and without stress risers, and the entire session should take about 1h. On the hard drive you
will find both 2D and 3D Solidworks drawings for 5 components (A, B, C, D, E), as a minimum you will
use A & B for this particular assignment, answering all questions in the following sections.

(A) plain (B) with 2 mm (C) with 5 mm (D) with single- (E) with
central hole central hole sided semi- double-sided
circular R2.5 semi-circular
mm notch R2.5 mm notch
Figure 1 – Samples used for assignment C2

For the assignment:

• Component A (plain dogbone) – Using work bench create a 2D Transient Structural analysis as
shown in the tutorial. Make sure that the 2D analysis type is selected for the geometry
component, and before undertaking any work within the Design Modeler (DM), make sure the
selected units are in mm. Import the 2D plain sample geometry into DM and click “Generate” to
see a body created under the 1 Part section of the tree outline. Follow the instructions in the
tutorial (as given in the back of this document and in the training session). Check that the
analysis type is 2D plane stress and that material thickness is 1mm.

Steps Instructions for work Answer the questions or

include in the assignment
1 Material properties Select stainless steel NL from the What is the Young’s Modulus
general nonlinear materials. of the material? (GPa)
Add a Tensile Ultimate Strength What is the Yield Strength of

EGA324 Course Notes 17 2018-19

 property of 512MPa. the material? (MPa)
What hardening flow rule
approximation is used?
2 Meshing On the Mesh select the sizing based on Add plots of the meshes used
“proximity and curvature” and select for each geometry.
“fine” under the Relevance Centre.
Under mesh create a sizing function
for the body (surface) and a
preliminary element size of 1mm.
3 Boundary Conditions Use a velocity of 1 mm/min and fix Add a plot which displays the
one end of the sample. fixed B.C. and the velocity
B.C.
4 Analysis settings Solve for up to 1200 seconds with a
minimum timestep of 0.1 s and
maximum timestep of 1 s.
5 Results For the finest mesh you used,
create
• a contour plot of the
maximum Von Misses
stress at t=1000s.
• a contour plot of the total
deformation (using 1:1
scaling)
• a contour plot of the
equivalent total strain
• export the Force reaction
curve to excel and plot
the force versus time for
the total reaction. What is
the reaction force at
yield?
• What is the maximum
total deformation at
yield?
6 Mesh sensitivity Try 2mm, 1.5mm and 1mm minimum What effect does mesh size
mesh size. have on the results?
Compare the maximum
displacement in all 3 cases at
t=1000s.
What happens to the
maximum deformation as the
mesh is refined?
7 Analysis sensitivity Cut and If the test sample were
1.5mm thick how what would
be the total reaction force at
yield?

• Component B (dogbone with single hole) – With the hole, what is the deformation at the yield
stress? Plot and add to your report contours of deformation and Von Misses stress for this
component at the yield stress. What is the location of highest stress? What is the location of

EGA324 Course Notes 18 2018-19

 highest strain? What is the stress concentration factor for this component? What is the effective
Young’s modulus?
Repeat the stress analysis process for the additional components (C-E) and compare the
computational results with your experimental results. You will need all the parts for the
experimental/computational comparison.
For the validation, use the 2D ANSYS models developed specifically using a derived isotropic
multilinear hardening curve. Modify this curve so that it matches the tensile data from your plain
samples – remember that this requires a true stress-strain curve.
Repeat the stress analysis this time including the test bars with stress raisers and compare the
computational results with your experimental results. You will need all the parts for the
experimental/computational comparison.
Compare the force-displacement curves for each of the components between experimental and
computational.
Compare the predicted elongation – rank the parts according the predicted elongation. How does
this compare to the experiment? Does mesh refinement make any difference to this order?
Calculate the stress concentration factors - how do the empirically, experimentally and
computationally calculated SCF for each of the stress raisers compare?

EGA324 Course Notes 19 2018-19

Technical Report Writing Guidelines

In general:

• Technical Reports are an important mode of communication in an Engineering environment

• Technical report writing is a skill that has to be developed
• The format and style of a Technical Report will vary from Organisation to Organisation
• A Technical Report must be structured and follow a logical form
• Use of headings and sub-headings is preferred
• Correct referencing is essential

Also, for students:

• Technical Reports include formal laboratory reports, design reports, undergraduate theses, PhD
dissertations, etc.
• They are used as a method of assessment
• Correct referencing is a very important issue
• Beware of plagiarism!

Requirements of a technical or laboratory report:

A technical report has three basic parts: Introduction, main body and conclusions

• Introduction – clear and concise statements, which set the scene

• Main body – the detail of the report
• Conclusions – the summing up
Very often, these three parts are sub-divided, see later.

Is written in the past imperfect tense

“We went to the library and collected information from a range of books and journals”
becomes
“Information was collected from a range of books and journals in the Library”

Uses technical language

“We fixed the bit of metal in the things that hold it at the top and bottom of the machine. Then my
friend switched on the machine and we made sure that all the instruments were reading 0. Then we
started to pull the bit of metal until it broke. The computer stored the information and made a stress-
strain curve on a piece of paper.”
should be:
“The tensile test specimen was fixed in the jaws of the testing machine. Having provided power to the
testing machine and its associated instrumentation, the load cell and strain gauge readings were
zeroed. The loading was then gradually increased and load cell and strain gauge data stored at

EGA324 Course Notes 20 2018-19

regular intervals in the computer. Once failure occurred, the stored data was manipulated to provide
a stress-strain curve, from which a hard copy was then plotted.”

Is well structured and ‘flows’

Bullet points are quite useful when explaining experimental procedures:-

o The tensile test specimen was fixed in the jaws of the testing machine
o Power was supplied to the testing machine and its associated instrumentation
o The load cell and strain gauge readings were zeroed
o The loading was gradually increased
o The load cell and strain gauge data was stored at regular intervals in the computer
o Once failure occurred, the stored data was manipulated to provide a stress-strain curve
o A hard copy of the stress-strain curve was obtained

Prepare an outline plan of headings and sub-headings before starting the

report

Use the three basic parts (i.e. Introduction, Main Body, Conclusions) approach
Use short sentences and avoid ‘waffle’
The suggested layout for a well-structured report is discussed later.

Contains well-structured sentences

“Shown in Figure 1 is the variation in stress across the plate”

should be
“The variation in stress across the plate is shown in Figure 1”
• Has all Pages, Tables, Figures and Equations numbered
i.e. Figure 3.2 is the second figure referred to in Section 3
Table 4.1 is the first table referred to in Section 4
Use the same numbering system for graphs and figures (graphs are referred to as ‘figures’)
Example of equation numbering
y = mx + c … (4)
Avoids ‘waffle’
“due to the fact that” is waffle, “because” is clear and concise

Must avoid Plagiarism

Plagiarism consists of passing off another student’s work as your own, without acknowledgement, in
order to gain an unfair advantage.
This includes material gathered from the Internet.
Plagiarism is also allowing your work to be used by another student (or students), who claims it to be
his or her own work.
Plagiarism can occur in all types of assessment including coursework, project reports, dissertations
and formal examinations (copying).

EGA324 Course Notes 21 2018-19

But, it does not include genuinely shared group projects.
Plagiarism is classed as UNFAIR PRACTICE by the University and will be penalised (which could
ultimately result in a student being required to withdraw from the University).
The two safe ways to avoid plagiarism are:-
✓ Ensure that any information obtained from another document is re-written in your own
words;
✓ Use references whenever quoting other information (see below).

Referencing

References are identified by means of superscripts placed at the appropriate points in the text
They are numbered in the order in which they first appear in the text
They are listed in the same order in the reference section of the report
For example:
“A substantial collection of appropriate design data has been presented by Peterson1 and reviewed
by Hardy and Malik2. In a recent survey3, it was found that this data is used extensively by designers
to predict the fatigue life of gear teeth”
References
1. PILKEY, W. D., Peterson’s stress concentration factors, Second Edition, 1997 (John Wiley, New
York).
2. HARDY, S. J. and MALIK, N. H., A survey of post-Peterson stress concentration factor data,
International Journal of Fatigue, 1992, 14(3), pp 147-153.
3. ALLISON, I. M. and HEARN, E. J., A new look at the bending strength of gear teeth, Experimental
Mechanics, 2003.
Note: If you are referencing a web page, you must give the address and the date it was last accessed
(as the information on a web page can change over time).

EGA324 Course Notes 22 2018-19

Summary of Rubric/Marking Schemes

C1 & C2 Assignment

EGA324 Course Notes 23 2018-19

C3 Assignment

EGA324 Course Notes 24 2018-19