Thermal analysis is the engineering discipline that examines heat distribution, temperature variations, and heat flow paths within a system.
From machine components to defense systems, from electronic circuits to pipelines, every structure reacts differently under thermal loads.
Therefore, thermal analysis is not only about determining temperatures — it also plays a key role in assessing strength, expansion, fatigue life, and safety factors.
At Fetech Advanced Engineering, we utilize ANSYS’s advanced thermal analysis modules to simulate real operating conditions digitally and verify the thermal performance of systems before production.
Heat transfer in engineering systems occurs through three primary mechanisms:
Conduction: Transfer of thermal energy within a solid material, governed by Fourier’s law:
where k is thermal conductivity and T is temperature distribution.
Convection: Heat exchange between a solid surface and a surrounding fluid (air, water, oil, etc.):
where h is the convection heat transfer coefficient.
Radiation: Emission or absorption of heat in the form of electromagnetic waves, significant at high temperatures.
In real-world systems, these three mechanisms often act simultaneously.
ANSYS enables engineers to model these effects together, providing a high-fidelity representation of heat transfer phenomena.
The process begins with importing the 3D or 2D model into ANSYS Workbench.
Unnecessary details are simplified, and symmetry conditions are applied to optimize computational efficiency.
Modules like CivilFEM for ANSYS can be used for structural or mechanical components to improve geometric accuracy and reduce preprocessing time.
Thermal material properties must be defined accurately:
Thermal Conductivity (k),
Density (ρ),
Specific Heat Capacity (cₚ).
ANSYS allows temperature-dependent properties to capture real material behavior under varying temperatures — for example, decreasing thermal conductivity in aluminum as temperature rises.
The Finite Element Method (FEM) divides the model into smaller elements to approximate temperature gradients across the domain.
In ANSYS Meshing, regions with steep temperature gradients (like edges or thin fins) require a denser mesh, while uniform areas can use a coarser grid.
This balance ensures both accuracy and computational efficiency.
Defining realistic boundary conditions is essential for meaningful results:
Fixed Temperature (e.g., surface maintained at 200°C)
Heat Flux (specified heat rate through a surface)
Convection (defined h value and ambient temperature)
Radiation (surface-to-surface or surface-to-environment)
Internal Heat Generation (e.g., electronic components or motors)
These inputs should represent the actual operating environment of the system.
ANSYS offers two main thermal analysis modes:
Steady-State Thermal Analysis:
Calculates the equilibrium temperature distribution where no further temperature change occurs over time.
Ideal for systems in constant operation such as heat exchangers or pipelines under steady flow.
Transient Thermal Analysis:
Evaluates time-dependent temperature variations.
Suitable for processes like engine startup or component cooling.
In transient cases, correct time-step definition and initial conditions are crucial.
Once solved, ANSYS provides comprehensive outputs such as:
Temperature contours,
Heat flux vectors,
Thermal gradients,
Energy balance data.
The Post-Processing module enables visualization through 3D color maps, animations, and quantitative probes — essential for identifying hot spots or critical areas.
In most engineering systems, temperature change not only affects heat distribution but also induces mechanical deformation and stress.
Examples include:
Expansion of brake discs under heating,
Thermal stress in electronic solder joints,
Structural distortion in metallic frameworks due to heat exposure.
With ANSYS Mechanical, such effects can be captured through Coupled Thermal-Structural Analysis, allowing the engineer to evaluate thermal stresses and deformations resulting from temperature variations.
At Fetech, we apply ANSYS-based thermal simulations across multiple industries:
Defense Industry:
Analysis of high-temperature performance in mission-critical systems (e.g., barrier mechanisms, torpedo handling systems).
Automotive:
Thermal validation of brake systems, exhaust components, and battery cooling units.
Machinery and Manufacturing:
Prediction of deformation and thermal gradients during molding, welding, or casting.
Pipeline and Pressure Vessels:
Evaluation of heat loss, insulation requirements, and thermal stresses in piping systems.
All simulations integrate ANSYS Mechanical, Fluent, and CivilFEM modules for end-to-end multiphysics fidelity.
Define realistic boundary conditions (convection coefficients, ambient temperatures).
Use temperature-dependent material data to reflect real-world physics.
Ensure high-quality meshing, especially near critical heat gradients.
Validate energy balance — total input heat equals total output heat in steady-state conditions.
Correlate results with experimental or analytical data for verification.
Thermal analysis is one of the most crucial aspects of modern engineering design.
With ANSYS, this process becomes not just a calculation, but a physically meaningful simulation that empowers better design decisions.
At Fetech Advanced Engineering, our thermal simulations help to:
Shorten R&D timelines,
Reduce prototype and testing costs,
Enhance product reliability and safety.
Through advanced thermal modeling and multiphysics simulation, we bring engineering innovation to life.