Course Overview

DIYguru presents a certification program on Fundamentals of ANSYS (FEA / FEM). This program provides you with the most flexible learning environment possible. This program is offered as a self-paced program often referred to as an asynchronous online program which is time-independent, meaning that it can be accessed 24X7 within the tenure of 30 days. This program can be accessed from multiple devices which makes it easy to learn on the go. Lectures that are pre-recorded or slide presentation with voice-over commentary, interactive discussion boxes that foster student to student interaction, Email communication with the instructor are part of this process.

Course Syllabus

  • Introduction to CAD CAM CAE
  • Introduction to ANSYS
  • Pre-Analysis
  • Verifying and Validating your Model
  • ANSYS Installation Guide (Official Student Version)
  • ANSYS Interface
  • What is FEA and FEM
  • Nodes and Elements
  • Degrees of Freedom (DOF)
  • Classification of Materials
  • Isotropic and Orthotropic Materials
  • Implicit and Explicit Analysis
  • Understanding the Project Page and Engineering Data
  • First Simulation in ANSYS Mechanical
  • Accessing ANSYS Workbench Help
  • Importing CAD Geometry
  • Geometry Clean-up and Simplification Part 1
  • Geometry Clean-up and Simplification Part 2
  • Geometry Clean-up and Simplification Part 3
  • Creating New Geometry Using ANSYS SpaceClaim
  • Creating and Editing Coordinate Systems
  • Meshing Fundamentals Part 1
  • Meshing Fundamentals Part 2
  • Meshing Fundamentals Part 3
  • Meshing Fundamentals Part 4
  • Setting-Up a Static Structural Analysis Part 1
  • Setting-Up a Static Structural Analysis Part 2
  • Boundary Conditions
  • Material Selection Criteria
  • Running Analysis and Results

Who is this program for?

  • This is an Intermediate Level Course. Students and Professionals from Engineering streams such as Mechanical, Automobile, Electronics and anyone who is familiar with the concepts of High School level Physics, Differentials, Integral Calculus along with some Basic Matrix Algebra can take this course.
  • Having a Diploma, BE / B.Tech or equivalent in domains such as Automotive, Mechanical, EEE, ECE, Instrumentation, Mechatronics, and Aeronautics.
  • Designing enthusiasts (No academic qualification mandatory)
  • Working in industries such as Automotive, Auto component, Design, Manufacturing, etc.
  • Working in Functional areas such as R&D, Analysis, Maintenance, Projects, component design, etc.
  • Interested in pursuing further studies on the part-time or full-time basis in Design and Engineering Sector.

Specialized roles one can apply for after doing this course

This programme is tailored to help you improve your engineering skills as a student, recent graduate, or working professional with following expertise.

  • R&D Engineer
  • Thermal Modeling
  • CFD Engineer
  • CAD Designer
  • Mechanical Designer
  • FEA Analyst
  • Structural Analyst
  • Simulation Engineer
  • CAE Engineer
  • Product Development Engineer
  • Engineering Consultant
  • Simulation Specialist
  • R&D Engineer, 
  • FEA Engineer
  • Fluid Dynamics Analysis Engineer
  • Sales And Executive-Cooling/Heating System
  • Design Engineer
  • Aerospace Engineer
  • Automotive Engineer
  • Product Manager
  • Design Manager
  • Manufacturing Engineer
  • Process Engineer
  • Quality Control Engineer
  • Test Engineer
  • Materials Engineer
  • Structural Design Engineer
  • Application Engineer
  • Thermal Management System Engineer
  • CAD Design and Modeling
  • FEA and Structural Analysis
  • CAE and Product Simulation
  • Engineering Consultancy
  • Research and Development (R&D)
    Product
  • Design and Development
  • Aerospace Engineering
  • Automotive Engineering
  • Industrial Engineering
  • Manufacturing Process Optimization

Industry overview 

  • Product complexity is increasing. Companies are under constant pressure to innovate, shorten cycle times, cut costs, raise quality, and take on less risk. The whole engineering industry, from digital exploration to digital prototyping to digital twins, is becoming more “pervasive” due to simulation.
  • Ansys simulation gives engineers the ability to explore and predict how products will work — or won’t work — in the real world. It’s like being able to see the future, enabling engineers to innovate as never before.

Benefits for Professionals and Freshers

For Professionals:

  • Enhancement of simulation skills for complex engineering problems, increasing value in R&D and product development roles.
  • Broadening knowledge of CAD/CAE tools, enabling more efficient and accurate design processes.
  • Gaining proficiency in ANSYS, a widely recognized tool in the industry, making them more competitive in the job market.

For Freshers:

  • Acquiring industry-relevant skills in CAD, FEA, and CAE, providing a strong foundation for a career in engineering.
  • Gaining practical experience with ANSYS, improving employability in fields like aerospace, automotive, and manufacturing.
  • Building a portfolio of projects that demonstrate ability to apply theoretical knowledge to real-world engineering challenges.

Languages & Tools Covered

  • ANSYS Mechanical, ANSYS Fluent and other ANSYS Software Tools

+ Internships/Projects included with this course

Project 1: Simulation of Battery Thermal Management in Electric Vehicle

 

Thermal management of battery systems in electric vehicles is critical for preserving energy storage capacity, driving range, cell longevity and system safety. Lithium-Ion cells represent the cutting-edge technology in energy storage for electric vehicles (EVs) and plug-in hybrid electric vehicles (PHEVs). Because of the current high costs and limited energy density, existing cells must be used to the fullest potential. By maximizing battery lifetime and facilitating the ideal operating conditions, electric vehicle range and lifetime can be maximized. 

Lithium-Ion cells are inherently subject to aging not only over time, but also due to operating conditions influences including their state of charge (SOC), current, and extreme temperatures. These factors have varied effects on the multitude of cell chemistries in use today, but temperature has a universal influence on the performance degradation of nearly all Lithium-Ion chemistries. The high cell currents mandated by consumer requirements such as rapid charging during performance driving result in high heat losses in the cells. Not only the average or maximum temperature in a cell influences aging, but also the temperature gradient across a cell or module. Premature aging of a single cell can degrade the performance of a module noticeably. 

The goal of a battery thermal management system (BTMS) is to increase the lifetime of Lithium-Ion cells and thus the battery system by regulating the temperature level and distribution. A BTMS is especially necessary when the cells are susceptible to high rates of charging (e.g., rapid charging or regenerative breaking) and discharging (e.g., high performance vehicles, plug-in hybrids), and when the vehicle is operated in very high or low ambient temperatures.

Project 2: CFD Study of Cooling Mechanism for Batteries

Various cooling agents and methods are in use today as part of the thermal management of EV batteries. Among these are air cooling, the use of flowing liquid coolants, or direct immersion. The lowest cost method for EV battery cooling is with air. A passive air-cooling system uses outside air and the movement of the vehicle to cool the battery. Active air-cooling systems enhance this natural air with fans and blowers. Air cooling eliminates the need for cooling loops and any concerns about liquids leaking into the electronics. The added weight from using liquids, pumps and tubing is also avoided. The trade-off is that air cooling, even with high-powered blowers, does not transport the same level of heat as a liquid system can. This has led to problems for EV in hot climates, including more temperature variation in battery pack cells. Blower noise can also be an issue.
Design of thermal management solutions requires extensive knowledge of cooling systems and the amount of heat generated by cells throughout the battery pack. Engineers must also weigh various trade-offs and factors such as cost, packaging, manufacturability, efficiency, reliability of heat dissipation components, and battery pack as an integrated, modular system. Batteries require a unique range of issues be taken into consideration. First, detailed models and sub-models are needed to simulate the chemical and physical phenomena inside battery cells. Then, these models need to be tied into a system-level model of a battery pack, which can comprise hundreds of cells and cooling circuits. Finally, the battery pack model needs to be integrated with the system model of the entire powertrain and vehicle.

Project 3: Vibration and Fatigue Analysis of Battery Pack

The battery pack in electric vehicles is subjected to road-induced vibration and this vibration is one of the potential causes of battery pack failure, especially once the road-induced frequency is close to the natural frequency of the battery when resonance occurs in the cells. If resonance occurs, it may cause notable structural damage and deformation of cells in the battery pack.
Battery packs incorporate many mechanical, electrical, and electrochemical component systems. They comprise thousands of discrete cells that are connected in series and parallel to electrical busbars to supply the required energy capacity. Cells are often welded together to complete the electrical path. These welds are highly susceptible to vibration and suffer from vibration-induced fatigue damage. Furthermore, a combination of lightweight support structures with relatively heavy electrochemical components can result in mechanical resonance in the battery structure with a high risk of fatigue cracking.
Vibration fatigue analysis enables engineers to identify the critical fatigue failure points on all types of battery structure, materials, welds, and joining technologies.

Project 4: Simulation of Structural Integrity of Motor Mount

An electric vehicle uses electric motors as the power source. The motors are coupled to mechanical drive train with the help of transmission system. Designing of a gear box casing and other mounts for differential and motor is one the primary tasks for development of an efficient transmission system for power transmission. These casing and mounts support the components and mitigate the vibrations that occur during the motion.
Mounts are the supporting members for motor and differential which are welded to the chassis or at times bolted. Mounts have to withstand varying loads, vibrations, shock loads when the vehicle is in motion. Stresses are induced into the body and failure might occur due to fatigue induced in the mounts.

Project 5: Thermal Analysis of Liquid Cooled Radiator

Liquid cooling is the most popular cooling technology. It uses a liquid coolant such as water, a refrigerant, or ethylene glycol to cool the battery. The liquid goes through tubes, cold plates, or other components that surround the cells and carry heat to another location, such as a radiator or a heat exchanger. Components carrying the liquid prevent direct electrical contact between the cells and the liquid coolant.
A liquid battery-cooling system works somewhat the same way as that of an internal-combustion engine. The coolant fluid is pumped through passages in the battery – usually inside a plate that cools the battery overall, or around the cells themselves. As with a gasoline engine’s system, the fluid gets hot as it cools the battery, and is cooled in a heat exchanger – basically a small radiator – and then recirculated in a closed loop. That loop may include cooling other electronic components. The waste heat may also be used to help warm the cabin in winter.
In addition to thermal management during driving, the liquid system also protects the battery during charging, especially when fast-charging on a DC charger. All charging creates heat, but the extra load of fast-charging can make a lot of it – including in the charger itself, which circulates its own coolant through its charging cable to regulate its temperature. The vehicle monitors its battery’s temperature during charging. If the cooling system isn’t doing enough, the vehicle will reduce its charging rate to bring down the temperature, especially if it’s a hot day. The battery will take longer to charge, but it’ll be better protected.