Thermal Failure Mapping Tool
Models thermal-fatigue behavior in aerospace forging dies and embedded avionics to identify failure-prone zones under cyclic heat loads. Workflow couples ANSYS Fluent for transient fields with Python post-processing to track damage accumulation and drive compact cooling design changes.
ANSYS Fluent
Python
Transient Thermal
Low-cycle Fatigue
Design of Experiments
- Simulated degradation in die steels under repeated high-temperature cycles.
- Mapped hotspots using temperature gradients, dwell times, and thermal stress proxies.
- Optimized cooling with finned, channel, and embedded heat-spreader variants.
- Automated analysis (Python) for fatigue metrics, envelopes, and report plots.
Method Overview
- Import CAD → conformal mesh with inflation layers.
- Apply transient boundary profiles (heat input / convection).
- Solve cycles; export fields (T, q", σeq if coupled).
- Python: hotspot clustering, dwell/gradient metrics, fatigue index.
- Compare variants; rank by life-extension vs. mass/complexity.
Snapshot (Placeholder)
Replace with: isotherms + hotspot overlay, cycle N vs. N+Δ, and cooling variant comparison.
Plots will appear here after validation.
Last updated: October 2025