Double-Wall Mug Thermal Analysis

Modeled a two-layer mug with a ceramic outer shell, stainless steel inner liner, and insulating air gap. Simulations evaluated cooling and thermal stress under different convection conditions.

Case A air convection thermal plot — Case A: 40°F air convection.

Case B water convection thermal plot — Case B: 50°F water convection.

Simulation setup

Initial mug temperature: 175°F
300-second transient thermal study
5-second nonlinear stress time step
Outer surfaces exposed to convection

23W/m²K air convection

350W/m²K water convection

300 sStudy duration

304 SSInner liner

CeramicOuter shell

Stress concentration reduction

Geometry changes were used to reduce thermally induced stress peaks.

Baseline thermal stress, Case A — Baseline stress, Case A.

Baseline thermal stress, Case B — Baseline stress, Case B.

Initial inner liner cross-section — Initial liner.

Updated inner liner with thicker lip and fillets — Updated liner.

Design changes

Doubled the inner-liner lip thickness and added fillets at the liner base to reduce sharp stress concentration locations.

Updated thermal stress, Case A — Updated stress, Case A.

Updated thermal stress, Case B — Updated stress, Case B.