Application of finite element software to bridge the gap between hand calculations and experimental results in undergraduate heat transfer education

A project involving the design, building, and testing of a hot liquid thermos was implemented in a junior level mechanical engineering heat transfer class. Finite element analysis (FEA) software was used to bridge the typical gap between hand calculations of heat transfer performance and experimental results. On average, student hand calculations over-predicted the thermos's thermal resistance by 124% as compared to experimental results. FEA, in the hand of undergraduate students, over-predicted the thermal resistance by only 33%. Student self-assessment survey results showed an overall positive feeling regarding the project. Despite the increased accuracy of FEA, 60% of students indicated that hand calculations were a more useful design tool, 65% indicated that they learned the most from hand calculations, and 75% indicated that hand calculations would be the future method of choice when heat transfer problems arise.