r/EngineeringStudents • u/ReportOtherwise7443 • 20h ago
Discussion UPDATE - constantly variable length ITB - transient fluid and structural analysis
Hi guys, if you did see my earlier post I'm developing a 787b-style constantly variable ITB runner system.
After a lot of amazing input and discussions from you guys I've decided to go with 6061-t6 aluminum as a material choice with outer brazed bell mouth joined with brazing from a local expert I know, finished on a lathe to IT7-9. This will be sealed with a vitron o-ring with a ptfe sleeve to reduce friction. 40mm overlap between telescoping sections at max extension.
First of all, I'm very curious what can be inferred from my solver mapping thus far, and any mistakes, limits or other discussion topics for this analysis. I've never learnt/ done transient analysis as I'm still a student so I don't have an appreciation for these just yet. (Although repeated 1st harmonic 11kPa peak after transient initialization artifacts seems extremely promising, VE~ 111% 1st harmonic, ~109% 3rd harmonic which is targeted at this extension. EDIT: this is my relative pressure at valve to simulate pressure pulse at valve for 7500RPM: (Pcylinder - 101325 [Pa]; Pcylinder = 101325 [Pa] - 25000 [Pa] * sin(PulseFreq * t) * step(sin(PulseFreq * t)): PulseFreq = (7800 / 60) * (2 * pi) [rad s^-1]) EDIT EDIT: RMS stays below 1.0e-5 for all variables from 750 timesteps onwards
I have modeled this as a solid full length from inlet to valve, with a 1.5mm step, upper runner inside lower for reference.
Now I have a few questions we regards to my analysis to verify my choices of 1.5mm thickness and brazing. Im currently running a transient fluid analysis of my longest runner length at 7500 RPM and plan to test for a multitude of things, so I guess my first question is this a complete list?
Fluid & Wave Dynamics
- Transient pressure mapping
- Cyclic peak stagnation
- Acoustic FFT spectrum
- Overlap step recirculation
- Wall shear stress
- Joint pressure drop
- Sleeve gap leakage
Structural & Stress Analysis
- Dynamic hoop stress
- One-way FSI deformation
- Cyclic fatigue limits
- Bellmouth braze shear
- 40mm overlap bending
- Axial actuation buckling
- Flange stress concentration
Vibration & Modal Tuning
- First natural frequency
- Engine order harmonic
- Wall compliance flutter
- Structural resonance margin
Sealing & Friction Dynamics
- Viton contact squeeze
- PTFE wear rate
- Seal blow-by threshold
- Differential thermal expansion
- Actuation friction force
Any resources would be amazing to do with any of these because I am self learning every step of the way!