Farzad Mirshams, Mechanical / Thermal Engineer

Some Samples of My Previous Design, Simulation & Test Projects, and Product Development Responsibilities

By: Farzad Mirshams, M.S.M.E.Professional Industry Experience: 25 Yrs

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Air Velocity (LFPM) Measurement Results for Air Flow Through the Chassis Slots. Measurements Were Taken Using Hot Wire Anemometer Probe.

Air Velocity (LFPM) Measurement Results for Air Flow Through the Chassis Slots. Measurements Were Taken Using Hot Wire Anemometer Probe.

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M23-17inch-Rev01 HEAT LOADS

CPU Chip 48 W

GPU Chip 12 W

U3-Bridge Chip 10 W

Motherboard PCB Uniform Spread 45 W

DIMM 4 W

Display Panel 15 W

HDD 13 W

ODD 7 W

Power Supply 30 W

Fans 4W X 3 =12 W

TOTAL 196 W

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Thermal Analysis, Digeo Inc

Electronic Cooling Solutions Inc612 National Avenue, Mountain View, CA 94043 Phone: (650) 988-1155

Farzad Mirshams2/10/05

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Model Description

Physical Model

• Chassis Size (inside dimensions): 16.9 inch X 2.5 inch X 11.5 inch

• Chassis Material: 0.03 inch thick, cold rolled steel

• PCB Assembly: 0.063 inch thick FR4 / 8 layers. Effective (board averaged) in-plane, and normal to the plane conductivities modeled. Critical heat dissipating components are modeled as isothermal blocks with uniform volumetric heat generation

• Fan: Panasonic, Panaflo FBA06A12M1A, 60 X 60 X 25.5 mm / 16.6 CFM / 3.95 mmH2O / 28 dB-A / Hydro Wave Bearing. Fan curve modeled

• Hard Drive: modeled as hollow blocks with uniform heat generation inside a thin conductive outer shell, and in dry metal on metal contact with the chassis inside surface

• Power Supply: modeled as a porous “sponge” block with uniform volumetric heat generation. Flow impedance along the three axes is characterized using quadratic loss coefficients

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Fig-1: Two Proposed layouts for Chassis Assembly are Modeled, Isometric Views

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Fig-2: Two Proposed Layouts Modeled, Side Views

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Fig-3: Grille Areas, as Modeled

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Model Description

Boundary Conditions

• Ambient Temperature: 40 C

• Chassis Top Surface: Natural convection & Radiation

• Chassis Bottom Surface: Radiation only

• Chassis Sides: Natural convection & Radiation

• Chassis Front Panel / Bezel: Insulated

• Chassis Rear Panel: Intake & Exhaust Grilles (65% open area ratio)

• Natural convection from external chassis surfaces are modeled using empirical film coefficients for horizontal, and vertical plates

• Radiation from external chassis surfaces are assumed to an infinite black body at the ambient temperature

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Model Description

Heat Loads / Power Dissipation

HD 12.5 W

PCB ASSEMBLY 70 W (Fig-4 & 5)

POWER SUPPLY 30 W

FAN <1.5 W (ignored)

TOTAL 112.5 W

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Fig-4: PCB assembly power dissipation, Top Side

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Fig-5: PCB assembly power dissipation, Bottom Side

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Model Results

• Total volumetric airflow thru the chassis: 12.1 CFM

• Mean processor heat sink's base temperature: 68.6 C

• Mean rear exhaust temperature: 52.4 C

• Temperature and air velocity plots are shown on the following slides:

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Fig-1: Modified Chassis Assembly Model, Fan Orientation Changed, Top View

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Model Results

• Total volumetric airflow thru the chassis: 12.4 CFM

• Mean exhaust temperature: 51.8 C

• Mean air temperature thru the fan: 45.6 C

• Mean processor heat sink’s base temperature: 69.0 C

• Mean HDD skin temperature: 53.9 C

• Total volumetric airflow thru the chassis: 12.2 CFM

• Mean exhaust temperature: 52.9 C

• Mean air temperature thru the fan: 48.4 C

• Mean processor heat sink’s base temperature: 76.8 C

• Mean HDD skin temperature: 54.9 C

Fan Blowing Air on the PCB:

Fan Pulling Air on the PCB

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Fig-1: XCVRs Shelf Natural Frequency & Modes Of Vibration

Fig-2: XCVRs Shelf Static Deflection, and Von Mises Stress; Total Load: 97 lbs.

Fig-1: MicroCITE Chassis Front Cover(Door) Static Deflection

Fig-1: Bracket Stress Analysis

Fig-1: XCVR-PA Aluminum Casting FEA Thermal Analysis

Figure-1: Proposed 60K Load-Lock Chamber ModelFig-1: Load-Lock Vacuum Chamber Structural/FEA Analysis

F.Mirshams 4/28/2006

FEA Modeling of Proposed 60K Test Stand Load-Lock Chamber, Case Studies

Model Description

CASE #1:

Side Plates Thickness: 3.0 inch

Top/Bottom Plates Thickness: 3.5 inch

Lid-Cover Thickness: 3.5 inch

Lid-Cover Rib Design: NO RIBS

CASE #2:

Side Plates Thickness: 3.0 inch

Top/Bottom Plates Thickness: 3.5 inch

Lid-Cover Thickness: 3.5 inch

Lid-Cover Rib Design: Open Web, 4 inch tall

CASE #3:

Side Plates Thickness: 3.0 inch

Top/Bottom Plates Thickness: 3.5 inch

Lid-Cover Thickness: 3.5 inch

Lid-Cover Rib Design: Open Web, 5 inch tall

CASE #4:

Side Plates Thickness: 3.0 inch

Top/Bottom Plates Thickness: 3.5 inch

Lid-Cover Thickness: 3.5 inch

Lid-Cover Rib Design: Closed Web, 4 inch tall

CASE #5:

Side Plates Thickness: 3.5 inch

Top/Bottom Plates Thickness: 4.0 inch

Lid-Cover Thickness: 3.5 inch

Lid-Cover Rib Design: Closed Web, 5 inch tall

The 60K load-lock model is shown in Figure-1. Five proposed design variations were modeled, as listed below:

F.Mirshams 4/28/06

• The assumed model boundary conditions are shown in Figure-2. Only 1/2 of the actual assembly was

modeled, taking advantage of symmetry in the geometry, and boundary conditions.

• The maintenance access opening’s bolted-in cover plate is not considered structurally significant,

thus it is not included in the model.

• Load-Lock chamber and lid-cover are made of Aluminum 6061-T6, with the following properties:

– Elastic Modulus = 10.0e+6 psi

– Poisson’s Ratio = 0.33

– Density = 0.0981 lb/in**3

• The computed deformation plots, and deformation animation movies are displayed in the follow up

slides.

FEA Modeling of Proposed 60K Test Stand Load-Lock Chamber, Case Studies

Figure-2: Assumed Boundary Conditions for the proposed 60K Load-Lock FEA Model

Bolted Fixed Frame Support Areas are shown in teal color

Surface Pressure Areas are shown in blue color

Surface Pressure Areas are shown in blue color

Figure-3: A Typical FEA Mesh for the proposed 60K Load-Lock Model

ANSYS Element Types Used:1. SOLID 187 / 10 Nodes Tetrahedral / Quadratic Displacement Function2. CONTA174 & TARGE170 / Surface to Surface Contact Pair (Frictionless Non-

Bonded Contact Option)

# of Nodes: 367,956

# of Elements: 233,188

Figure-4: A Typical FEA Mesh for the proposed 60K Load-Lock Model

ANSYS Element Types Used:1. SOLID 187 / 10 Nodes Tetrahedral / Quadratic Displacement Function2. CONTA174 & TARGE170 / Surface to Surface Contact Pair (Frictionless Non-

Bonded Contact Option)

# of Nodes: 392,225

# of Elements: 248,743

CASE #3:

Side Plates Thickness: 3.0 inch

Top/Bottom Plates Thickness: 3.5 inch

Lid-Cover Thickness: 3.5 inch

Lid-Cover Rib Design: Open Web, 5 inch tall

Figure-13: Deformation

CASE #2:

Side Plates Thickness: 3.0 inch

Top/Bottom Plates Thickness: 3.5 inch

Lid-Cover Thickness: 3.5 inch

Lid-Cover Rib Design: Open Web, 4 inch tall Figure-12: Von-Mises Stress

CASE #2:

Side Plates Thickness: 3.0 inch

Top/Bottom Plates Thickness: 3.5 inch

Lid-Cover Thickness: 3.5 inch

Lid-Cover Rib Design: Open Web, 4 inch tall

Figure-8: Deformation in the Y-Direction

CASE #4:

Side Plates Thickness: 3.0 inch

Top/Bottom Plates Thickness: 3.5 inch

Lid-Cover Thickness: 3.5 inch

Lid-Cover Rib Design: Closed Web, 4 inch tall

Figure-15: Deformation in the Y-Direction

CASE #5:

Side Plates Thickness: 3.5 inch

Top/Bottom Plates Thickness: 4.0 inch

Lid-Cover Thickness: 3.5 inch

Lid-Cover Rib Design: Closed Web, 5 inch tall

Figure-22: Deformation in the X-Direction

F.Mirshams 4/16/2006

FEA Modeling of 60K/50K Ceramic Assemblies / Camlock CB Hole Size Study

• Two proposed design variations were modeled, per CAD files listed below:

• 1. CAD file: “60K 125 taper 17 shaft 8 cbored camlocks”• 2. CAD file: “50K assembly larger camlock cbores”

• Two levels of structural modeling were performed for each assembly, as follows:

• 1. The ceramic assembly was modeled as fully-bonded parts composing a single ceramic piece. Thus no possible gapping or slippage between assembly parts were allowed in the model.

• 2. The ceramic assembly was modeled as separate piece parts in non-bonded frictionless contact, using ANSYS surface to surface contact elements. Thus assembly parts could flex individually causing gaps to form.

• The assumed model boundary conditions are shown in the follow up slides. Only ¼ of the actual assembly was modeled, taking advantage of symmetry in the geometry, and boundary conditions.

• Locating pins & camlock fasteners are not considered structurally significant, thus they were not included in the model.

• Assembly parts are made of COORSTEK / AD-96 Ceramic material with the following properties:• Elastic Modulus = 44.0e+6 psi• Poisson’s Ratio = 0.21• Density = 0.135 lb/in**3

• The computed Maximum Principal stress plots are displayed in the follow up slides.

Model Description

Boundary Conditions, CAD Model: “60K 125 taper 17 shaft 8 cbored camlocks”

ANSYS Element Types Used:1. SOLID 187 / 10 Nodes Tetrahedral / Quadratic Displacement Function2. CONTA174 & TARGE170 / Surface to Surface Contact Pair (Frictionless Non-Bonded Contact Option)

Fully Bonded Model Mesh

# of Nodes: 42,689# of Elements: 24,900

Non-Bonded Model Mesh

# of Nodes: 127,683# of Elements: 80,227

CAD Model: “60K 125 taper 17 shaft 8 cbored camlocks”

Max Deformation = 0.095 inch

CAD Model: “60K 125 taper 17 shaft 8 cbored camlocks”

C/Bore size: 1.0” Diameter, 0.125” Round

Fully Bonded Model

C/Bore size: 1.0” Diameter, 0.125” Round

C/Bore size: 1.0” Diameter, 0.125” Round

CAD Model: “60K 125 taper 17 shaft 8 cbored camlocks”

Non-Bonded Model, “Gaps Allowed”

Max Deformation = 0.17 inch

Max Gap = 0.013 inch

C/Bore size: 1.0” Diameter, 0.125” Round

CAD Model: Modified “60K 125 taper 17 shaft 8 cbored camlocks”

Non-Bonded Model, “Gaps Allowed”

C/Bore size: 2.0” Diameter, 0.25” Round

C/Bore size: 2.0” Diameter, 0.25” Round

C/Bore size: 1.0” Diameter, 0.125” Round, Location Change C/Bore size: 1.5” Diameter, 0.25” Round, Location change

0.25” Round0.125” Round

Boundary Conditions, CAD Model: “50K assembly larger camlock cbores”

ANSYS Element Types Used:1. SOLID 187 / 10 Nodes Tetrahedral / Quadratic Displacement Function2. CONTA174 & TARGE170 / Surface to Surface Contact Pair (Frictionless Non-Bonded Contact Option)

Fully Bonded Model Mesh

# of Nodes: 25,285# of Elements: 14,166

Non-Bonded Model Mesh

# of Nodes: 106,222# of Elements: 66,124

CAD Model: “50K assembly larger camlock cbores”

CAD Model: “50K assembly larger camlock cbores”

Fully Bonded Model

Max Deformation = 0.12 inch

CAD Model: “50K assembly larger camlock cbores”

Non-Bonded Model, “Gaps Allowed”

Max Deformation = 0.22 inch

Max Gap = 0.019 inch

F.Mirshams 6/12/2006

FEA Modeling of 25K Ceramic Assembly

• The FEA model is created per CAD file listed below:

• CAD file: “25K IPS Support Ceramics”

• Two possible loading configuration for the ceramic plates, by the Susceptor, were modeled:

• 1. Susceptor’s weight is supported evenly between the outer ceramic plates load pad areas

• 2. Susceptor’s weight is supported evenly by the outer ceramic plates load pad areas, and an Aluminum shim at the main ceramic plate’s center hole

• The assumed model boundary conditions are shown in the follow up slides. Only ¼ of the actual assembly was modeled, taking advantage of symmetry in the geometry, and boundary conditions. Locating pins & camlock fasteners are not considered structurally significant, thus they were not included in the model.

Ceramic assembly parts are made of COORSTEK / AD-96 with the following properties:

• Elastic Modulus = 44.0e+6 psi

• Poisson’s Ratio = 0.21

• Density = 0.135 lb/in**3

Center shim is made of Aluminum-6061 with the following properties:

• Elastic Modulus = 10.0e+6 psi

• Poisson’s Ratio = 0.33

• Density = 0.0981 lb/in**3

• The computed deformation & Maximum Principal stress plots are displayed in the follow up slides.

Model Description

Boundary Conditions, CAD Model: “25K IPS Support Ceramics”

Bonded Contact

Non-bonded Contact

Bonded Contact

Non-bonded Contact

No Center Shim With Center Shim

“With Center Shim” Model Mesh

# of Nodes: 157,753# of Elements: 93,598

CAD Model: “25K IPS Support Ceramics”

ANSYS Element Types Used:1. SOLID 187 / 10 Nodes Tetrahedral / Quadratic Displacement Function2. CONTA174 & TARGE170 / Surface to Surface Contact Pair (Frictionless Non-Bonded Contact Option)

Deformation, No Center Shim

Deformation, With Center Shim

CAD Model: “25K IPS Support Ceramics”

With Center Shim

CAD Model: “25K IPS Support Ceramics”