MECHANICAL ENGINEERING A Series of Textbooks and Reference Books Founding Editor L L Faulkner Columbus Division, Battelle Memorial Institute and Department of Mechanical Engineering The Ohio State University Columbus, Ohio 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Spring Designer’s Handbook, Harold Carlson Computer-Aided Graphics and Design, Daniel L Ryan Lubrication Fundamentals, J George Wills Solar Engineering for Domestic Buildings, William A Himmelman Applied Engineering Mechanics: Statics and Dynamics, G Boothroyd and C Poli Centrifugal Pump Clinic, Igor J Karassik Computer-Aided Kinetics for Machine Design, Daniel L Ryan Plastics Products Design Handbook, Part A: Materials and Components; Part B: Processes and Design for Processes, edited by Edward Miller Turbomachinery: Basic Theory and Applications, Earl Logan, Jr Vibrations of Shells and Plates, Werner Soedel Flat and Corrugated Diaphragm Design Handbook, Mario Di Giovanni Practical Stress Analysis in Engineering Design, Alexander Blake An Introduction to the Design and Behavior of Bolted Joints, John H Bickford Optimal Engineering Design: Principles and Applications, James N Siddall Spring Manufacturing Handbook, Harold Carlson Industrial Noise Control: Fundamentals and Applications, edited by Lewis H Bell Gears and Their Vibration: A Basic Approach to Understanding Gear Noise, J Derek Smith Chains for Power Transmission and Material Handling: Design and Applications Handbook, American Chain Association Corrosion and Corrosion Protection Handbook, edited by Philip A Schweitzer Gear Drive Systems: Design and Application, Peter Lynwander Controlling In-Plant Airborne Contaminants: Systems Design and Calculations, John D Constance CAD/CAM Systems Planning and Implementation, Charles S Knox Probabilistic Engineering Design: Principles and Applications, James N Siddall 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 Traction Drives: Selection and Application, Frederick W Heilich III and Eugene E Shube Finite Element Methods: An Introduction, Ronald L Huston and Chris E Passerello Mechanical Fastening of Plastics: An Engineering Handbook, Brayton Lincoln, Kenneth J Gomes, and James F Braden Lubrication in Practice: Second Edition, edited by W S Robertson Principles of Automated Drafting, Daniel L Ryan Practical Seal Design, edited by Leonard J Martini Engineering Documentation for CAD/CAM Applications, Charles S Knox Design Dimensioning with Computer Graphics Applications, Jerome C Lange Mechanism Analysis: Simplified Graphical and Analytical Techniques, Lyndon O Barton CAD/CAM Systems: Justification, Implementation, Productivity Measurement, Edward J Preston, George W Crawford, and Mark E Coticchia Steam Plant Calculations Manual, V Ganapathy Design Assurance for Engineers and Managers, John A Burgess Heat Transfer Fluids and Systems for Process and Energy Applications, Jasbir Singh Potential Flows: Computer Graphic Solutions, Robert H Kirchhoff Computer-Aided Graphics and Design: Second Edition, Daniel L Ryan Electronically Controlled Proportional Valves: Selection and Application, Michael J Tonyan, edited by Tobi Goldoftas Pressure Gauge Handbook, AMETEK, U.S Gauge Division, edited by Philip W Harland Fabric Filtration for Combustion Sources: Fundamentals and Basic Technology, R P Donovan Design of Mechanical Joints, Alexander Blake CAD/CAM Dictionary, Edward J Preston, George W Crawford, and Mark E Coticchia Machinery Adhesives for Locking, Retaining, and Sealing, Girard S Haviland Couplings and Joints: Design, Selection, and Application, Jon R Mancuso Shaft Alignment Handbook, John Piotrowski BASIC Programs for Steam Plant Engineers: Boilers, Combustion, Fluid Flow, and Heat Transfer, V Ganapathy Solving Mechanical Design Problems with Computer Graphics, Jerome C Lange Plastics Gearing: Selection and Application, Clifford E Adams Clutches and Brakes: Design and Selection, William C Orthwein Transducers in Mechanical and Electronic Design, Harry L Trietley Metallurgical Applications of Shock-Wave and High-Strain-Rate Phenomena, edited by Lawrence E Murr, Karl P Staudhammer, and Marc A Meyers Magnesium Products Design, Robert S Busk 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 How to Integrate CAD/CAM Systems: Management and Technology, William D Engelke Cam Design and Manufacture: Second Edition; with cam design software for the IBM PC and compatibles, disk included, Preben W Jensen Solid-State AC Motor Controls: Selection and Application, Sylvester Campbell Fundamentals of Robotics, David D Ardayfio Belt Selection and Application for Engineers, edited by Wallace D Erickson Developing Three-Dimensional CAD Software with the IBM PC, C Stan Wei Organizing Data for CIM Applications, Charles S Knox, with contributions by Thomas C Boos, Ross S Culverhouse, and Paul F Muchnicki Computer-Aided Simulation in Railway Dynamics, by Rao V Dukkipati and Joseph R Amyot Fiber-Reinforced Composites: Materials, Manufacturing, and Design, P K Mallick Photoelectric Sensors and Controls: Selection and Application, Scott M Juds Finite Element Analysis with Personal Computers, Edward R Champion, Jr and J Michael Ensminger Ultrasonics: Fundamentals, Technology, Applications: Second Edition, Revised and Expanded, Dale Ensminger Applied Finite Element Modeling: Practical Problem Solving for Engineers, Jeffrey M Steele Measurement and Instrumentation in Engineering: Principles and Basic Laboratory Experiments, Francis S Tse and Ivan E Morse Centrifugal Pump Clinic: Second Edition, Revised and Expanded, Igor J Karassik Practical Stress Analysis in Engineering Design: Second Edition, Revised and Expanded, Alexander Blake An Introduction to the Design and Behavior of Bolted Joints: Second Edition, Revised and Expanded, John H Bickford High Vacuum Technology: A Practical Guide, Marsbed H Hablanian Pressure Sensors: Selection and Application, Duane Tandeske Zinc Handbook: Properties, Processing, and Use in Design, Frank Porter Thermal Fatigue of Metals, Andrzej Weronski and Tadeusz Hejwowski Classical and Modern Mechanisms for Engineers and Inventors, Preben W Jensen Handbook of Electronic Package Design, edited by Michael Pecht Shock-Wave and High-Strain-Rate Phenomena in Materials, edited by Marc A Meyers, Lawrence E Murr, and Karl P Staudhammer Industrial Refrigeration: Principles, Design and Applications, P C Koelet Applied Combustion, Eugene L Keating Engine Oils and Automotive Lubrication, edited by Wilfried J Bartz 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 Mechanism Analysis: Simplified and Graphical Techniques, Second Edition, Revised and Expanded, Lyndon O Barton Fundamental Fluid Mechanics for the Practicing Engineer, James W Murdock Fiber-Reinforced Composites: Materials, Manufacturing, and Design, Second Edition, Revised and Expanded, P K Mallick Numerical Methods for Engineering Applications, Edward R Champion, Jr Turbomachinery: Basic Theory and Applications, Second Edition, Revised and Expanded, Earl Logan, Jr Vibrations of Shells and Plates: Second Edition, Revised and Expanded, Werner Soedel Steam Plant Calculations Manual: Second Edition, Revised and Expanded, V Ganapathy Industrial Noise Control: Fundamentals and Applications, Second Edition, Revised and Expanded, Lewis H Bell and Douglas H Bell Finite Elements: Their Design and Performance, Richard H MacNeal Mechanical Properties of Polymers and Composites: Second Edition, Revised and Expanded, Lawrence E Nielsen and Robert F Landel Mechanical Wear Prediction and Prevention, Raymond G Bayer Mechanical Power Transmission Components, edited by David W South and Jon R Mancuso Handbook of Turbomachinery, edited by Earl Logan, Jr Engineering Documentation Control Practices and Procedures, Ray E Monahan Refractory Linings Thermomechanical Design and Applications, Charles A Schacht Geometric Dimensioning and Tolerancing: Applications and Techniques for Use in Design, Manufacturing, and Inspection, James D Meadows An Introduction to the Design and Behavior of Bolted Joints: Third Edition, Revised and Expanded, John H Bickford Shaft Alignment Handbook: Second Edition, Revised and Expanded, John Piotrowski Computer-Aided Design of Polymer-Matrix Composite Structures, edited by Suong Van Hoa Friction Science and Technology, Peter J Blau Introduction to Plastics and Composites: Mechanical Properties and Engineering Applications, Edward Miller Practical Fracture Mechanics in Design, Alexander Blake Pump Characteristics and Applications, Michael W Volk Optical Principles and Technology for Engineers, James E Stewart Optimizing the Shape of Mechanical Elements and Structures, A A Seireg and Jorge Rodriguez Kinematics and Dynamics of Machinery, Vladimír Stejskal and Michael Valásek Shaft Seals for Dynamic Applications, Les Horve Reliability-Based Mechanical Design, edited by Thomas A Cruse Mechanical Fastening, Joining, and Assembly, James A Speck 110 Turbomachinery Fluid Dynamics and Heat Transfer, edited by Chunill Hah 111 High-Vacuum Technology: A Practical Guide, Second Edition, Revised and Expanded, Marsbed H Hablanian 112 Geometric Dimensioning and Tolerancing: Workbook and Answerbook, James D Meadows 113 Handbook of Materials Selection for Engineering Applications, edited by G T Murray 114 Handbook of Thermoplastic Piping System Design, Thomas Sixsmith and Reinhard Hanselka 115 Practical Guide to Finite Elements: A Solid Mechanics Approach, Steven M Lepi 116 Applied Computational Fluid Dynamics, edited by Vijay K Garg 117 Fluid Sealing Technology, Heinz K Muller and Bernard S Nau 118 Friction and Lubrication in Mechanical Design, A A Seireg 119 Influence Functions and Matrices, Yuri A Melnikov 120 Mechanical Analysis of Electronic Packaging Systems, Stephen A McKeown 121 Couplings and Joints: Design, Selection, and Application, Second Edition, Revised and Expanded, Jon R Mancuso 122 Thermodynamics: Processes and Applications, Earl Logan, Jr 123 Gear Noise and Vibration, J Derek Smith 124 Practical Fluid Mechanics for Engineering Applications, John J Bloomer 125 Handbook of Hydraulic Fluid Technology, edited by George E Totten 126 Heat Exchanger Design Handbook, T Kuppan 127 Designing for Product Sound Quality, Richard H Lyon 128 Probability Applications in Mechanical Design, Franklin E Fisher and Joy R Fisher 129 Nickel Alloys, edited by Ulrich Heubner 130 Rotating Machinery Vibration: Problem Analysis and Troubleshooting, Maurice L Adams, Jr 131 Formulas for Dynamic Analysis, Ronald L Huston and C Q Liu 132 Handbook of Machinery Dynamics, Lynn L Faulkner and Earl Logan, Jr 133 Rapid Prototyping Technology: Selection and Application, Kenneth G Cooper 134 Reciprocating Machinery Dynamics: Design and Analysis, Abdulla S Rangwala 135 Maintenance Excellence: Optimizing Equipment Life-Cycle Decisions, edited by John D Campbell and Andrew K S Jardine 136 Practical Guide to Industrial Boiler Systems, Ralph L Vandagriff 137 Lubrication Fundamentals: Second Edition, Revised and Expanded, D M Pirro and A A Wessol 138 Mechanical Life Cycle Handbook: Good Environmental Design and Manufacturing, edited by Mahendra S Hundal 139 Micromachining of Engineering Materials, edited by Joseph McGeough 140 Control Strategies for Dynamic Systems: Design and Implementation, John H Lumkes, Jr 141 Practical Guide to Pressure Vessel Manufacturing, Sunil Pullarcot 142 Nondestructive Evaluation: Theory, Techniques, and Applications, edited by Peter J Shull 143 Diesel Engine Engineering: Thermodynamics, Dynamics, Design, and Control, Andrei Makartchouk 144 Handbook of Machine Tool Analysis, Ioan D Marinescu, Constantin Ispas, and Dan Boboc 145 Implementing Concurrent Engineering in Small Companies, Susan Carlson Skalak 146 Practical Guide to the Packaging of Electronics: Thermal and Mechanical Design and Analysis, Ali Jamnia 147 Bearing Design in Machinery: Engineering Tribology and Lubrication, Avraham Harnoy 148 Mechanical Reliability Improvement: Probability and Statistics for Experimental Testing, R E Little 149 Industrial Boilers and Heat Recovery Steam Generators: Design, Applications, and Calculations, V Ganapathy 150 The CAD Guidebook: A Basic Manual for Understanding and Improving Computer-Aided Design, Stephen J Schoonmaker 151 Industrial Noise Control and Acoustics, Randall F Barron 152 Mechanical Properties of Engineered Materials, Wolé Soboyejo 153 Reliability Verification, Testing, and Analysis in Engineering Design, Gary S Wasserman 154 Fundamental Mechanics of Fluids: Third Edition, I G Currie 155 Intermediate Heat Transfer, Kau-Fui Vincent Wong 156 HVAC Water Chillers and Cooling Towers: Fundamentals, Application, and Operation, Herbert W Stanford III 157 Gear Noise and Vibration: Second Edition, Revised and Expanded, J Derek Smith 158 Handbook of Turbomachinery: Second Edition, Revised and Expanded, edited by Earl Logan, Jr and Ramendra Roy 159 Piping and Pipeline Engineering: Design, Construction, Maintenance, Integrity, and Repair, George A Antaki 160 Turbomachinery: Design and Theory, Rama S R Gorla and Aijaz Ahmed Khan 161 Target Costing: Market-Driven Product Design, M Bradford Clifton, Henry M B Bird, Robert E Albano, and Wesley P Townsend 162 Fluidized Bed Combustion, Simeon N Oka 163 Theory of Dimensioning: An Introduction to Parameterizing Geometric Models, Vijay Srinivasan 164 Handbook of Mechanical Alloy Design, edited by George E Totten, Lin Xie, and Kiyoshi Funatani 165 Structural Analysis of Polymeric Composite Materials, Mark E Tuttle 166 Modeling and Simulation for Material Selection and Mechanical Design, edited by George E Totten, Lin Xie, and Kiyoshi Funatani 167 Handbook of Pneumatic Conveying Engineering, David Mills, Mark G Jones, and Vijay K Agarwal 168 Clutches and Brakes: Design and Selection, Second Edition, William C Orthwein 169 Fundamentals of Fluid Film Lubrication: Second Edition, Bernard J Hamrock, Steven R Schmid, and Bo O Jacobson 170 Handbook of Lead-Free Solder Technology for Microelectronic Assemblies, edited by Karl J Puttlitz and Kathleen A Stalter 171 Vehicle Stability, Dean Karnopp 172 Mechanical Wear Fundamentals and Testing: Second Edition, Revised and Expanded, Raymond G Bayer 173 Liquid Pipeline Hydraulics, E Shashi Menon 174 Solid Fuels Combustion and Gasification, Marcio L de Souza-Santos 175 Mechanical Tolerance Stackup and Analysis, Bryan R Fischer 176 Engineering Design for Wear, Raymond G Bayer 177 Vibrations of Shells and Plates: Third Edition, Revised and Expanded, Werner Soedel 178 Refractories Handbook, edited by Charles A Schacht 179 Practical Engineering Failure Analysis, Hani M Tawancy, Anwar Ul-Hamid, and Nureddin M Abbas 180 Mechanical Alloying and Milling, C Suryanarayana 181 Mechanical Vibration: Analysis, Uncertainties, and Control, Second Edition, Revised and Expanded, Haym Benaroya 182 Design of Automatic Machinery, Stephen J Derby 183 Practical Fracture Mechanics in Design: Second Edition, Revised and Expanded, Arun Shukla 184 Practical Guide to Designed Experiments, Paul D Funkenbusch 185 Gigacycle Fatigue in Mechanical Practive, Claude Bathias and Paul C Paris 186 Selection of Engineering Materials and Adhesives, Lawrence W Fisher 187 Boundary Methods: Elements, Contours, and Nodes, Subrata Mukherjee and Yu Xie Mukherjee 188 Rotordynamics, Agnieszka (Agnes) Muszn ´yska 189 Pump Characteristics and Applications: Second Edition, Michael W Volk 190 Reliability Engineering: Probability Models and Maintenance Methods, Joel A Nachlas 191 Industrial Heating: Principles, Techniques, Materials, Applications, and Design, Yeshvant V Deshmukh 192 Micro Electro Mechanical System Design, James J Allen 193 Probability Models in Engineering and Science, Haym Benaroya and Seon Han 194 Damage Mechanics, George Z Voyiadjis and Peter I Kattan 195 Standard Handbook of Chains: Chains for Power Transmission and Material Handling, Second Edition, American Chain Association and John L Wright, Technical Consultant 196 Standards for Engineering Design and Manufacturing, Wasim Ahmed Khan and Abdul Raouf S.I 197 Maintenance, Replacement, and Reliability: Theory and Applications, Andrew K S Jardine and Albert H C Tsang 198 Finite Element Method: Applications in Solids, Structures, and Heat Transfer, Michael R Gosz 199 Microengineering, MEMS, and Interfacing: A Practical Guide, Danny Banks 200 Fundamentals of Natural Gas Processing, Arthur J Kidnay and William Parrish 201 Optimal Control of Induction Heating Processes, Edgar Rapoport and Yulia Pleshivtseva 202 Practical Plant Failure Analysis: A Guide to Understanding Machinery Deterioration and Improving Equipment Reliability, Neville W Sachs, P.E 203 Shaft Alignment Handbook, Third Edition, John Piotrowski 204 Advanced Vibration Analysis , S Graham Kelly 205 Principles of Composite Materials Mechanics, Second Edition, Ronald F Gibson 206 Applied Combustion, Second Edition, Eugene L Keating 207 Introduction to the Design and Behavior of Bolted Joints, Fourth Edition: Non-Gasketed Joints, John H Bickford 208 Analytical and Approximate Methods in Transport Phenomena, Marcio L de Souza-Santos 209 Design and Optimization of Thermal Systems, Second Edition, Yogesh Jaluria Boca Raton London New York CRC Press is an imprint of the Taylor & Francis Group, an informa business MATLAB® is a trademark of The MathWorks, Inc and is used with permission The MathWorks does not warrant the accuracy of the text or exercises in this book This book’s use or discussion of MATLAB® software or related products does not constitute endorsement or sponsorship by The MathWorks of a particular pedagogical approach or particular use of the MATLAB® software CRC Press Taylor & Francis Group 6000 Broken Sound Parkway NW, Suite 300 Boca Raton, FL 33487-2742 © 2008 by Taylor & Francis Group, LLC CRC Press is an imprint of Taylor & Francis 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the CRC Press Web site at http://www.crcpress.com 2007027214 Contents Chapter Introduction 1.1 Engineering Design 1.1.1 Design Versus Analysis 1.1.2 Synthesis for Design 1.1.3 Selection Versus Design 1.2 Design as Part of Engineering Enterprise 1.2.1 Need or Opportunity 1.2.2 Evaluation and Market Analysis 10 1.2.3 Feasibility and Chances of Success 12 1.2.4 Engineering Design 14 1.2.5 Research and Development 15 1.2.6 Need for Optimization 16 1.2.7 Fabrication, Testing, and Production 18 1.3 Thermal Systems 19 1.3.1 Basic Characteristics 19 1.3.2 Analysis 22 1.3.3 Types and Examples 25 1.4 Outline and Scope of the Book 40 1.5 Summary 43 References 44 Chapter 2.1 2.2 2.3 Basic Considerations in Design 47 Formulation of the Design Problem 47 2.1.1 Requirements and Specifications 47 2.1.2 Given Quantities 50 2.1.3 Design Variables 51 2.1.4 Constraints or Limitations 53 2.1.5 Additional Considerations 55 Conceptual Design 58 2.2.1 Innovative Conceptual Design 58 2.2.2 Selection from Available Concepts 62 2.2.3 Modifications in the Design of Existing Systems 64 Steps in the Design Process 70 2.3.1 Physical System 72 2.3.2 Modeling 75 2.3.3 Simulation 76 2.3.4 Evaluation: Acceptable Design 81 2.3.5 Optimal Design 83 2.3.6 Safety Features, Automation, and Control 86 2.3.7 Communicating the Design 90 2.3.8 Patents and Copyrights 92 2.4 Computer-Aided Design 97 2.4.1 Main Features 97 2.4.2 Computer-Aided Design of Thermal Systems 98 2.5 Material Selection 104 2.5.1 Different Materials 104 2.5.2 Material Properties and Characteristics for Thermal Systems 108 2.5.3 Selection and Substitution of Materials .110 2.6 Summary 113 References 115 Problems 116 Chapter 3.1 Modeling of Thermal Systems 125 Introduction 125 3.1.1 Importance of Modeling in Design 125 3.1.2 Basic Features of Modeling 125 3.2 Types of Models 128 3.2.1 Analog Models 129 3.2.2 Mathematical Models 130 3.2.3 Physical Models 130 3.2.4 Numerical Models 131 3.2.5 Interaction Between Models 133 3.2.6 Other Classifications 133 3.3 Mathematical Modeling 134 3.3.1 General Procedure 134 3.3.2 Final Model and Validation 160 3.4 Physical Modeling and Dimensional Analysis 165 3.4.1 Dimensional Analysis 166 3.4.2 Modeling and Similitude .176 3.4.3 Overall Physical Model 180 3.5 Curve Fitting 180 3.5.1 Exact Fit .181 3.5.2 Best Fit 183 3.6 Summary 194 References 196 Problems 197 Chapter Numerical Modeling and Simulation 207 4.1 Numerical Modeling 208 4.1.1 General Features 208 4.1.2 Development of a Numerical Model 210 4.1.3 Available Software .211 4.2 Solution Procedures 212 4.2.1 Linear Algebraic Systems 213 4.2.2 Nonlinear Algebraic Systems 220 4.2.3 Ordinary Differential Equations 227 4.2.4 Partial Differential Equations 238 4.3 Numerical Model for a System 247 4.3.1 Modeling of Individual Components 248 4.3.2 Merging of Different Models 251 4.3.3 Accuracy and Validation 252 4.4 System Simulation 253 4.4.1 Importance of Simulation 254 4.4.2 Different Classes 256 4.4.3 Flow of Information 259 4.5 Methods for Numerical Simulation 264 4.5.1 Steady Lumped Systems 264 4.5.2 Dynamic Simulation of Lumped Systems 272 4.5.3 Distributed Systems 278 4.5.4 Simulation of Large Systems 282 4.5.5 Numerical Simulation Versus Real System 283 4.6 Summary 284 References 285 Problems 286 Chapter 5.1 5.2 5.3 5.4 Acceptable Design of a Thermal System: A Synthesis of Different Design Steps 299 Introduction 299 Initial Design 300 Design Strategies 309 5.3.1 Commonly Used Design Approach 309 5.3.2 Other Strategies 309 5.3.3 Iterative Redesign Procedure 317 Design of Systems from Different Application Areas 322 5.4.1 Manufacturing Processes 323 5.4.2 Cooling of Electronic Equipment 329 5.4.3 Environmental Systems 336 5.4.4 Heat Transfer Equipment 342 5.4.5 Fluid Flow Systems 350 5.4.6 Other Areas 361 5.4.7 Design of Components Versus Design of Systems 361 5.5 Additional Considerations for Large Practical Systems 362 5.6 Summary 373 References 374 Problems 375 Chapter Economic Considerations 383 6.1 6.2 Introduction 383 Calculation of Interest 385 6.2.1 Simple Interest 385 6.2.2 Compound Interest 385 6.2.3 Continuous Compounding 387 6.2.4 Effective Interest Rate 388 6.3 Worth of Money as a Function of Time 390 6.3.1 Present Worth 390 6.3.2 Future Worth 391 6.3.3 Inflation 393 6.4 Series of Payments 396 6.4.1 Future Worth of Uniform Series of Amounts 396 6.4.2 Present Worth of Uniform Series of Amounts 397 6.4.3 Continuous Compounding in a Series of Amounts 399 6.4.4 Changing Amount in Series of Payments 400 6.4.5 Shift in Time 402 6.4.6 Different Frequencies 403 6.4.7 Changes in Schedule 403 6.5 Raising Capital 405 6.5.1 Bonds 406 6.5.2 Stocks 408 6.6 Taxes 408 6.6.1 Inclusion of Taxes 409 6.6.2 Depreciation 410 6.7 Economic Factor in Design 413 6.7.1 Cost Comparison 413 6.7.2 Rate of Return 417 6.8 Application to Thermal Systems 419 6.9 Summary 421 References 421 Problems 422 Chapter 7.1 Problem Formulation for Optimization 429 Introduction 429 7.1.1 Optimization in Design 429 7.1.2 Final Optimized Design .431 7.2 Basic Concepts 432 7.2.1 Objective Function 432 7.2.2 Constraints 434 7.2.3 Operating Conditions Versus Hardware 437 7.2.4 Mathematical Formulation 438 7.3 Optimization Methods 440 7.3.1 Calculus Methods 440 7.3.2 Search Methods 441 7.3.3 Linear and Dynamic Programming 442 7.3.4 Geometric Programming 444 7.3.5 Other Methods 444 7.4 Optimization of Thermal Systems 447 7.4.1 Important Considerations 447 7.4.2 Different Approaches 448 7.4.3 Different Types of Thermal Systems 449 7.4.4 Examples 451 7.4.5 Consideration of the Second Law of Thermodynamics 455 7.5 Practical Aspects in Optimal Design 457 7.5.1 Choice of Variables for Optimization 457 7.5.2 Sensitivity Analysis 459 7.5.3 Dependence on Objective Function: Trade-Offs 461 7.5.4 Multi-Objective Optimization 462 7.5.5 Part of Overall Design Strategy 464 7.5.6 Change of Concept or Model 465 7.6 Summary 466 References 467 Problems 468 Chapter 8.1 8.2 8.3 8.4 8.5 Lagrange Multipliers 473 Introduction to Calculus Methods 473 The Lagrange Multiplier Method 475 8.2.1 Basic Approach 475 8.2.2 Physical Interpretation 477 8.2.3 Significance of the Multipliers 485 Optimization of Unconstrained Problems 486 8.3.1 Use of Gradients for Optimization 487 8.3.2 Determination of Minimum or Maximum 487 8.3.3 Conversion of Constrained to Unconstrained Problem 489 Optimization of Constrained Problems 491 Applicability to Thermal Systems 494 8.5.1 Use of Curve Fitting 494 8.5.2 Examples 495 8.5.3 Inequality Constraints 499 8.5.4 Some Practical Considerations 500 8.5.5 Computational Approach 501 8.6 Summary 503 References 504 Problems 505 Chapter Search Methods 511 9.1 Basic Considerations 511 9.1.1 Importance of Search Methods 512 9.1.2 Types of Approaches 513 9.1.3 Application to Thermal Systems 514 9.2 Single-Variable Problem 515 9.2.1 Uniform Exhaustive Search 517 9.2.2 Dichotomous Search 519 9.2.3 Fibonacci Search 521 9.2.4 Golden Section and Other Search Methods 523 9.2.5 Comparison of Different Elimination Methods 524 9.3 Unconstrained Search with Multiple Variables 527 9.3.1 Lattice Search 529 9.3.2 Univariate Search 530 9.3.3 Steepest Ascent/Descent Method 532 9.4 Multivariable Constrained Optimization 537 9.4.1 Penalty Function Method 537 9.4.2 Search Along a Constraint 542 9.5 Examples of Thermal Systems 547 9.6 Summary 551 References 553 Problems 554 Chapter 10 Geometric, Linear, and Dynamic Programming and Other Methods for Optimization 559 10.1 Geometric Programming 559 10.1.1 Applicability 560 10.1.2 Unconstrained Optimization 561 10.1.3 Mathematical Proof 570 10.1.4 Constrained Optimization 573 10.1.5 Nonzero Degree of Difficulty 578 10.2 Linear Programming 579 10.3 Dynamic Programming 588 10.4 Other Methods 590 10.5 Summary 591 References 592 Problems 593 Chapter 11 Knowledge-Based Design and Additional Considerations 599 11.1 Knowledge-Based Systems 599 11.1.1 Introduction 600 11.1.2 Basic Components 602 11.1.3 Expert Knowledge 607 11.1.4 Design Methodology 609 11.1.5 Application to Thermal Systems 610 11.2 Additional Constraints 621 11.3 Professional Ethics 623 11.4 Sources of Information 625 11.5 An Overview of Design of Thermal Systems 628 11.6 Summary 631 References 632 Problems 633 Design Projects 635 Appendix A Computer Programs 639 Appendix B Material Properties 659 Appendix C Interest Tables 679 Appendix D Heat Transfer Correlations 687 Index 697 Preface to the First Edition APPROACH Design is an essential element in engineering education and practice In recent years, there has been a growing emphasis on the design and optimization of systems because of growing worldwide competition and the development of new processes and techniques Design has long been very important in undergraduate mechanical engineering curricula around the country However, the effort had been largely directed at mechanical systems, dealing with areas such as transmission, vibrations, robotics, and controls, and at components such as gears, cams, springs, and linkages With the growth of thermal systems, such as those related to materials processing, energy conversion, pollution, aerospace, and automobiles, the need to design and optimize thermal systems has also grown In mechanical engineering programs around the country, courses have been developed on the design of thermal systems These are often elective courses, or, in many schools, such courses form the final capstone design course, often alternated with a design course on mechanical systems Invariably, optimization is an important element in such courses because of the crucial need to optimize systems in practical applications This book is written as a textbook at the senior undergraduate or the first-year graduate level It can also be used as a reference book for other thermal sciences courses, such as those on heat transfer, fluid mechanics, and thermodynamics, and for courses in applied areas, such as power plants, environmental control of buildings, and solar energy systems It can be used for reference by practicing engineers as well Although the book is written for engineering education curricula in the United States, the material and treatment can easily be used in various countries around the world The book is largely written for mechanical engineers However, the material is suitable for courses in other engineering disciplines, such as chemical, aerospace, industrial, and materials engineering The book is directed at the design of thermal systems, employing examples from diverse areas such as manufacturing, energy systems, cooling of electronic equipment, refrigeration, environmental problems, engines, and heat transfer equipment Many such examples and an introduction to design are given in Chapter Then the conceptual design and formulation of the design problem are presented in Chapter 2, along with the main constituents of design, including material selection The design process, as predominantly based on the mathematical modeling of the system and on the results obtained from numerical simulation, is presented in the next three chapters Analytical results, if available, are valuable for validating the numerical model as well as for providing a fundamental basis for design The use of experimental data, mainly as correlations derived from curve fitting, is presented as an essential element in the design and optimization process The basic approach to the development of a suitable model is discussed in Chapter in detail since this forms the most crucial step in the design of a system Various approximations and idealizations that can be used for modeling are presented, along with examples of mathematical modeling of practical systems This is followed in Chapter by detailed discussions of numerical modeling and simulation, again linking these to the mathematical model and experimental data These results then form the basis for creative design of thermal systems and for the evaluation of the designs obtained The development of a workable, or acceptable, design, one which satisfies the requirements and constraints of the problem, is discussed as a synthesis of the different design steps Several examples are given in Chapter to illustrate the overall procedure This is followed in Chapter by a discussion of economic factors in design since these often guide system design and optimization The formulation of the optimization problem is explained in Chapter The presentation on optimization includes several applicable methods such as calculus methods, search methods, and linear, dynamic, and geometric programming These topics are covered in Chapter through Chapter 10 Again, thermal systems found in several important and relevant areas are used as examples to illustrate the ideas presented Solved examples and problems strengthen the presentation and allow the important concepts to be assimilated by the readers Recent trends, such as knowledge-based design methodology, are included in Chapter 11 Additional practical considerations, such as economic, safety, and materials, are also discussed at various stages of the presentation Therefore, the book starts with the basic design concept and develops the material through modeling and simulation stages of the thermal process and system on to the creation of a workable design The iterative process that is often used to obtain an acceptable design is presented This logically leads to optimization procedures and the improvement of the design to obtain the best possible solution under the given constraints The book offers a systematic approach, exploring the various considerations that lead to a workable and, finally, to an optimal design; uses up-to-date examples and problems, and presents the most current information and design tools available in this important field Examples range from simple systems to large, complex practical systems Synthesis of the various aspects that constitute design is discussed in detail A few relevant computer programs are included to help with the numerical modeling and simulation These include programs on curve fitting, solution of algebraic systems, and solution of simple differential equations Quantitative information on materials, economics, and heat transfer correlations is also included The mathematical modeling of systems is a particularly important aspect of design, though it is often neglected Modeling is presented with a wide range of physical examples and a discussion of the types of approximations that can be used to simplify the problem The inputs obtained from the model for an innovative and optimal design are outlined The main thrust of this book is to develop and discuss the basic considerations that arise in the design and optimization of thermal systems, as well as the appropriate methodology Readers are encouraged to use their own backgrounds, imaginations, and available literature for designing different types of systems Since simple closed-form, analytical, solutions are rarely obtained in practical thermal systems, clear and concise answers are not readily available in many cases A consideration of several practical systems makes this aspect of thermal system design clear The material included in this book has been used in courses for undergraduate seniors at Rutgers University and at the Indian Institute of Technology, Kanpur, India The topics, examples, and problems have, therefore, been largely tested in a classroom environment Various design projects and examples emerged from these courses, and some of them are included in the text In keeping with the basic design process, many of the problems are open-ended and a unique solution is not obtained SUPPLEMENT A solutions manual, prepared by me in order to ensure the problem-solving methodology is the same as that in the book, is available to text adopters This manual contains possible solutions to most of the problems in this book (since many problems are open-ended and thus not have a unique solution) ACKNOWLEDGMENTS Many colleagues, friends, and students have contributed in significant ways to the development of this material and to my understanding of the design process Of particular help have been the many discussions I have had with Professors V Sernas and N.A Langrana of Rutgers University on the design of systems My interactions with students over many years on design projects and on practical design problems have also provided important insights into the design process The comments of the manuscript reviewers and of Professor J R Lloyd of Michigan State University, the editor of this series, have been very valuable and helpful in organizing and presenting the material I would like to take the opportunity to thank each of the manuscript reviewers personally The reviewers are Jamal Seyed-Yagoobi, Texas A&M University; Andrew V Tangborn, Northeastern University; Edwin Griggs, Tennessee Technological University; Bakhtier Farouk, Drexel University; Donald Fenton, Kansas State University; John R Lloyd, Consulting Editor, Michigan State University; Donald C Raney, The University of Alabama; Jeffrey Hodgson, The University of Tennessee, Knoxville; Louis C Burmeister, The University of Kansas; Edward Vendell, Utah State University; Edward Hensel, New Mexico State University; Prasanna Kadaba, Georgia Institute of Technology The assistance provided by the staff of McGraw-Hill has also contributed very significantly to the book This book is dedicated to my parents, who have been a constant source of encouragement, support, and inspiration Certainly, the greatest contribution to this work has been the unqualified support and encouragement of my wife, Anuradha, and the patience and understanding of our children, Pratik, Aseem, and Ankur Without their support, it would not have been possible for me to meet the strong demands placed on my time by this book Yogesh Jaluria ... 600 11 .1. 2 Basic Components 602 11 .1. 3 Expert Knowledge 607 11 .1. 4 Design Methodology 609 11 .1. 5 Application to Thermal Systems 610 11 .2 Additional... Constraints 6 21 11. 3 Professional Ethics 623 11 .4 Sources of Information 625 11 .5 An Overview of Design of Thermal Systems 628 11 .6 Summary 6 31 References... The Ohio State University Columbus, Ohio 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Spring Designer’s Handbook, Harold Carlson Computer-Aided Graphics and Design, Daniel L Ryan Lubrication Fundamentals,