Design optimization of fluid dispersion systems with value engineering and simulation
K. Sreenu Babu,P. S. Chakraborty,S. Nallusamy,G. V. Punna Rao,K. Manogar
Abstract
A key goal of engineers working on industrial fluid management systems is to balance cost and performance. This research presents a methodology for redesign of a liquid dispersion unit using value engineering (VE) concepts and simulation-based analysis. The approach identifies high-cost, low-value components through Function-Cost-Worth Analysis (FCWA) and evaluates their impact with the Function Analysis System Technique (FAST) and evaluation matrices. Results showed that the nozzle subsystem was the main limitation, as it did not cover the spray area well and fluid dynamics were unsatisfactory. To address this, several nozzle shapes and materials were examined during the creative phase. A complete cone nozzle proved the best design. Computational Fluid Dynamics (CFD) confirmed improved flow properties, while Finite Element Analysis (FEA) showed structural adequacy under operational pressures. Polypropylene was selected as the best material since it is secure and significantly less costly compared to metals like gunmetal and stainless steel. The changes increased system efficiency from 63.75% to 75.25%, an 11.5% improvement, while overall cost decreased by 2.52%. This demonstrates that integrating VE with CAD-based simulations can generate innovative, scalable designs for fluid-based industrial systems.
Key Words
computational fluid dynamics; finite element analysis; function analysis system technique; value engineering
Address
K. Sreenu Babu, S. Nallusamy — 1Department of Adult, Continuing Education and Extension, Jadavpur University, Kolkata 700032, India
P. S. Chakraborty, G. V. Punna Rao — Department of Mechanical Engineering, Prakasam Engineering College, Kandukur, Andhra Pradesh 523105, India
K. Manogar — Department of Safety and Fire Engineering, K.S.R. College of Engineering, Tamilnadu 637215, India
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