vybhavverse - DRDO projects

Shaping Ideas, Stay Tuned!

During my undergraduate internship at the Defence Research and Development Organisation (DRDO) – Instruments Research & Development Establishment (IRDE), Dehradun, I spearheaded computational simulations to solve critical engineering challenges in defense systems.

Leveraging Finite Element Analysis (FEA) and Computational Fluid Dynamics (CFD), these projects focused on optimizing structural integrity and thermal performance under some design constraints.

Project 1: Design and Static Analysis of Payload Enclosure Using Finite Element Analysis (FEA)

Tools: SolidWorks Static, FFE+ Solver, CAD Modeling, Meshing Techniques

Overview:

Developed and optimized a lightweight aluminum alloy (Al-1060) enclosure for electro-optical payload systems (thermal imagers, CCDs, detectors) using static structural FEA. The goal was to minimize mass while ensuring deflection remained below 10 microns under gravitational and operational loads.

Preliminary model of non-ribbed enclosure

Preliminary model of ribbed enclosure

Key Contributions:n

Validated FEA framework by replicating analytical solutions for cantilever beam bending (≤2% error in stress/deflection predictions).
Designed a preliminary 3D enclosure model (3mm thickness) and iteratively optimized mass by 15% through rib reinforcement and topology studies.
Conducted convergence analysis (h/p-refinement) with 2nd–5th order shape functions to ensure solution accuracy within 1% tolerance.

Technical Approach:

FEA Validation:
1. Derived analytical solutions for bending stress/deflection in cantilever beams.
2. Simulated identical cases in SolidWorks with beam meshing, Al-1060 material properties, and iterative FFE+ solver.
3. Validated results against theory to confirm solver reliability.

Fixed base corners case (deflection)

Fixed base center case (deflection)

Fixed base-plate case (deflection)

Enclosure Optimization:
1. Applied fixed boundary conditions (base + corners) and gravitational loads.
2. Meshed with tetrahedral 3D elements, refining at stress-concentrated edges/cutouts.
3. Reduced mass via parametric studies on wall thickness and rib geometry, maintaining deflection ≤10 µm.

Convergence Assurance:
1. Executed h-type (mesh refinement) and p-type (higher-order shape functions) studies for result stability.

Outcomes:

Achieved 15% mass reduction while meeting strict deflection limits.
Enhanced proficiency in FEA workflows, design optimization, and validation for defense applications.

SOLIDWORKS Setup

2D Engineering Drawing of Enclosure

Project 2: CFD Analysis of Shell-and-Tube Heat Exchanger (STHX) for Thermal Performance Optimization

Tools: Solidworks Flow Simulation, Finite Volume Method (FVM), k-epsilon Turbulence Modeling

Overview:

Simulated a shell-and-tube heat exchanger (STHX) to evaluate heat transfer rates under varying flow configurations. Analyzed the impact of shell-side mass flow rates and tube-pass arrangements on thermal efficiency.

Key Contributions:n

Modeled two STHX configurations (1-pass vs. 2-pass tubes) using CAD data from literature.
Quantified heat transfer improvement by optimizing shell-side mass flow rates to maintain 70°C outlet temperature.
Validated results against published data to ensure solver accuracy.

Technical Approach:

CFD Setup:
1. Defined boundary conditions:
  1. Shell side: Hot water (prescribed inlet temperature, variable mass flow rates).
  2. Tube side: Cold water (constant mass flow rate).
2. Applied k-epsilon turbulence model for Reynolds-averaged Navier-Stokes (RANS) equations.

Full View of 1-2 pass STHX

Sectional View of 1-2 pass STHX

Parametric Study:
1. Varied shell-side mass flow rates to maximize heat transfer while meeting target outlet temperatures.
2. Compared thermal performance across tube-pass configurations.

Post-Processing:
1. Visualized temperature contours and velocity profiles.
2. Calculated heat transfer coefficients and pressure drop correlations.

Outcomes:

Identified optimal shell-side flow rates for maximizing heat transfer efficiency.
Gained expertise in FVM-based CFD workflows for thermal system design.

SOLIDWORKS Flow-Simulation Setup

Temperture vs Iteration plots of cold and hot fluids

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During my undergraduate internship at the Defence Research and Development Organisation (DRDO) – Instruments Research & Development Establishment (IRDE), Dehradun, I spearheaded computational simulations to solve critical engineering challenges in defense systems.

Leveraging Finite Element Analysis (FEA) and Computational Fluid Dynamics (CFD), these projects focused on optimizing structural integrity and thermal performance under some design constraints.

Project 1: Design and Static Analysis of Payload Enclosure Using Finite Element Analysis (FEA)

Overview:

Key Contributions:n

Technical Approach:

Outcomes:

Project 2: CFD Analysis of Shell-and-Tube Heat Exchanger (STHX) for Thermal Performance Optimization

Overview:

Key Contributions:n

Technical Approach:

Outcomes:

Get in touch at vaibhav19m345@gmail.com for any query.