Avva Sai Pranav

← Back to projects

Project · CAD/FEA

CAD Modeling & FEA Simulation Gallery

Johns Hopkins University | Personal Projects · 2024 – Present

11Mechanism animations
2FEA studies
5Software platforms
100kNCrash load validated
MEMS accelerometer finite element analysis showing displacement under applied force

This gallery showcases my CAD modeling and simulation capabilities, developed through coursework at Johns Hopkins University and independent practice. From classical mechanisms like Geneva drives and rack-and-pinion systems to advanced multi-physics FEA of EV batteries and MEMS accelerometers, this collection demonstrates proficiency across the full spectrum of mechanical design and analysis tools.

The collection includes mechanism animations demonstrating kinematic understanding—from simple pulleys and gears to complex Geneva mechanisms and multi-body assemblies. The FEA work ranges from macro-scale EV battery pack crash and thermal simulations to micro-scale MEMS accelerometer characterization including modal analysis, harmonic response, and electrostatic heating effects.

Software Proficiency

All work was completed using industry-standard tools across multiple platforms.

🔧 ANSYS 🔬 COMSOL ⚙️ Creo Simulate 📐 SolidWorks 🎨 Fusion 360

Mechanisms & Power Transmission

Kinematic animations of classical mechanical systems demonstrating motion conversion and power transmission principles.

Belt Drive System
Pulley system modeling with belt-driven animation showing power transmission mechanics
CAD Animation
Spur Gear Mesh
Spur gear mesh animation showing tooth engagement and rotational kinematics
CAD Animation
Geneva Mechanism
Geneva mechanism (Maltese cross) animation demonstrating intermittent rotary motion conversion
CAD Animation
Mass-Spring-Damper System
Mass-spring-damper pulley system animation showing dynamic mechanical response
CAD Animation
Rack and Pinion
Rack and pinion gear animation demonstrating linear-to-rotary motion conversion
CAD Animation
Lead Screw Mechanism
Lead screw mechanism animation showing rotational-to-linear translation with thread engagement
CAD Animation
Multi-Body Linkage
Complex multi-body mechanism animation demonstrating advanced kinematic linkages
CAD Animation

Mechanical Systems

Complete mechanical assembly models with working animations.

Crane Mechanism
Crane mechanism model with animated boom and cable assembly demonstrating multi-body kinematics
CAD Animation
Positive Displacement Pump
Positive displacement pump mechanism animation showing fluid handling components in motion
CAD Animation

FEA Projects

Comprehensive finite element analysis studies with detailed reports.

EV Battery Pack Multi-Physics Analysis
Creo Simulate
100,000 N Max Impact Load
1.09 mm Max Deformation
265°C Max Temperature
950 Hz 1st Resonant Freq
>100 Hz ✓ Safety Requirement
Structural (Crash Impact) Thermal (Rapid Discharge) Combined MEC/T Loads Dynamic Random Vibration Modal Analysis
Details Materials & highlights

Materials: Steel HSLA (casing), Nickel-Copper alloy (electrodes), Aluminum Wrought (cell proxies)

  • Battery pack validated for use as structural monocoque member
  • Thermal analysis based on Tesla 21700 cell specifications
  • Natural convection cooling analysis with recommendations for active cooling
Dual-Axis MEMS Capacitive Accelerometer
ANSYS/COMSOL
2867.7 Hz Eigenfrequency
3.7 µm/g Displacement Sensitivity
1.66 ΔC/g Capacitance Sensitivity
3.2 nm/g Cross-axis Sensitivity
492 Quality Factor
Modal Analysis (20 modes) Harmonic Response Static Structural (1G) Steady-State Thermal
Details Performance characterization

Achieved market-comparable specifications for MEMS accelerometer design with comprehensive multi-physics analysis including electrostatic heating effects and thermal-structural coupling.

Results

Key findings and demonstrated capabilities from this body of work.

Findings Key findings
  • Demonstrated proficiency across 5 industry-standard CAD/FEA platforms
  • Completed multi-physics analyses spanning structural, thermal, and dynamic domains
  • Modeled mechanisms covering all major motion conversion types (rotary, linear, intermittent)
  • Achieved market-comparable specifications for MEMS accelerometer design
  • Validated EV battery pack for crash safety requirements exceeding industry standards
Skills Technical skills demonstrated
  • CAD: Parametric modeling, Assembly animation, Mechanism design
  • FEA: Mesh generation and optimization, Boundary condition definition
  • Analysis: Modal and harmonic analysis, Thermal-structural coupling
  • Validation: Results interpretation and validation
Future Future scope
  • Expand MEMS analysis to include squeeze-film damping effects
  • Add CFD analysis for battery pack active cooling design
  • Create parametric mechanism library with configurable dimensions
  • Implement mesh convergence studies for higher confidence results
  • Explore topology optimization for lightweight structural designs

Additional Information

Downloadable FEA reports with complete methodology and results.

EV Battery Pack FEA Report

Complete analysis including crash, thermal, combined loads, and dynamic vibration studies

MEMS Accelerometer FEA Report

Complete performance characterization with modal, harmonic, and thermal analysis

Course Acknowledgements

FEA work completed as part of Johns Hopkins University - 535.632 Applied Finite Element Analysis Course.