Apply scientific principles and methodology to appreciate the engineering and scientific context of automotive and motorsport engineering

1 Learning Outcomes Assessed
LO1: Apply scientific principles and methodology to appreciate the engineering and scientific context of
automotive and motorsport engineering, and to understand relevant historical, current and future
developments and technologies. (SM1b)
3.2 Assessment Brief

Introduction
Hydrogen is a clean fuel that, when consumed in a fuel cell, produces only water. The Hydrogen Storage
Tank/Fuel Tank (Figure 1) is getting popular in the automotive industry.
A Hydrogen Fuel tank with all the dimensions is shown in Figure 2. This tank is designed to contain
compressed hydrogen at 240 Bar. The edge A of the tank is fixed in the axial direction and additionally,
edges A and B are fixed in the circumferential direction. The Tank is made up of AISI 1045 Steel, Cold drawn
with properties shown in Table 1.
Figure 1 Hydrogen Fuel tank inside a car.
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Figure 2 Hydrogen Fuel Tank.
Table 1 Properties of AISI 1045 Steel, Cold drawn.
Young’s modulus 205 GPa
Poisson’s ratio 0.29
Yield strength 530 MPa
Ultimate strength 625 MPa
Statement on the structural integrity of the Hydrogen Fuel Tank used in this assignment for the given
loading: Proof (Safety factor for yield stress) and ultimate (safety factor for ultimate tensile stress) factors
of 1.25 and 1.5 respectively shall be used.
The Hydrogen Fuel Tank is to be assessed for its structural integrity.
Instructions
Part I: FEA analysis using SolidWorks
1) Set up a finite element analysis (FEA) model for the wing using SolidWorks Simulation and
apply the appropriate boundary conditions. It is suggested that you use the approach of
Pressure Vessel.
2) Carry out initial checks
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3) Apply the following load in turn:
An internal pressure, 𝑃 of 240 Bar.
4) Now check your simulated results
Part II: Analytical calculations
Perform the analytical calculations below with the equations given:
Considering the Hydrogen Fuel Tank as a pressure vessel with an internal diameter of 𝑑 and
thickness of 𝑡.
a) the Hoop Stress (𝜎ℎ):
𝜎ℎ =
𝑃𝑑
2𝑡
b) the Longitudinal Stress (𝜎𝑙
):
𝜎ℎ =
𝑃𝑑
4𝑡
c) the Safety factors:
• Safety factor for yield strength (SF1):
𝑆𝐹1 =
𝜎𝑦𝑠
𝜎ℎ
• Safety factor for ultimate strength (SF2):
𝑆𝐹2 =
𝜎𝑈𝑇𝑆
𝜎ℎ
Where 𝜎𝑦𝑠 is yield strength and 𝜎𝑈𝑇𝑆 is ultimate strength of the material.
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Part III: Compare the FEA results with the analytical results.
Report Requirements
Write a short report to present your findings. Ensure that it includes the following:
(i) Front page (Title, name etc), content, Abstract, and Introduction including aim and
objectives of the assignment (10%).
(ii) Methodology (20%):
➢ Definition of geometry, loading conditions and constraints including figures
as you feel appropriate (10%).
➢ Details of the FE model – geometry, mesh and boundary conditions and
loading including plots (screenshots) as you feel appropriate (10%).
(iii) Results and Discussion (60%). These should include:
Part I: FEA analysis using SolidWorks
For the given internal pressure, determine using SolidWorks Simulation Including
plots (screenshots) as you feel appropriate:
➢ Hoop Stress (10%).
➢ Logitudinal Stress (10%).
Part II: Analytical calculations
For the given internal, determine using analytical calculations including figures as you
feel appropriate:
➢ Hoop Stress (10%).
➢ Logitudinal Stress (10%).
Part III: Compare the FEA results with the analytical results.
➢ A comparison of the FEA results with the analytical results from the initial
checks together with appropriate comments (10%).
➢ Also, comment on the Hoop Stress in the structure related to the given
properties of the aluminium alloy AISI 1045 Steel, Cold drawn (10%).
(iv) Conclusion and Reference (10%).
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Recommendations
➢ Page number, Header and Footer, Font: Calibri, Font size: 12, Line spacing: 2
➢ Ensure that you use Harvard referencing and provide minimum of 5
appropriate references.

Submission procedure
An electronic copy of the assignment in .pdf format needs to be uploaded via Turnitin in Moodle.
Also, send the SolidWorks Simulation file via email to m.mohin@bolton.ac.uk.
Assessment
This assignment constitutes 40% of the total assessment of the principal objectives of this unit