Search results for: electric discharge machining (EDM)

Authors: Faisal Islam, J. Ramkumar

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The applications of composite materials in aerospace, sporting and automotive industries need high quality machined surfaces and dimensional accuracy. Some studies have been done to understand the fiber failure mechanisms encountered during milling machining of CFRP composites but none are capable of explaining the exact nature of the orientation-based fiber failure mechanisms encountered in the milling machining process. The objective of this work is to gain a better understanding of the orientation-based fiber failure mechanisms occurring on the slot edges during CFRP milling machining processes. The occurrence of damage is predicted by a schematic explanation based on the mechanisms of material removal which in turn depends upon fiber cutting angles. A geometric model based on fiber cutting angle and fiber orientation angle is proposed that defines the critical and safe zone during machining and predicts the occurrence of delamination. Milling machining experiments were performed on composite samples of varying fiber orientations to verify the proposed theory. Mean fiber pulled out length was measured from the microscopic images of the damaged area to quantify the amount of damage produced. By observing the damage occurring for different fiber orientation angles and fiber cutting angles for up-milling and down-milling edges and correlating it with the material removal mechanisms as described earlier, it can be concluded that the damage/delamination mainly depends on the portion of the fiber cutting angles that lies within the critical cutting angle zone.

Keywords: unidirectional composites, milling, machining damage, delamination, carbon fiber reinforced plastics (CFRPs)

Procedia PDF Downloads 530

Authors: Dejan Tanikić, Miodrag Manić, Jelena Đoković, Saša Kalinović

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This paper deals with the determination of the optimum machining parameters, according to the measured and modelled data of the cutting temperature and surface roughness, during the turning of the AISI 4140 steel. The high cutting temperatures are unwanted occurences in the metal cutting process. They impact negatively on the quality of the machined part. The machining experiments were performed using different cutting regimes (cutting speed, feed rate and depth of cut), with different values of the workpiece hardness, which causes different values of the measured cutting temperature as well as the measured surface roughness. The temperature and surface roughness data were modelled after that using Response Surface Methodology (RSM). The obtained RSM models are used in the process of optimization of the cutting regimes using the Genetic Algorithms (GA) tool, which enables the metal cutting process in the optimum conditions.

Keywords: genetic algorithms, machining parameters, response surface methodology, turning process

Procedia PDF Downloads 188

Authors: Jana Petrů, Tomáš Zlámal, Robert Čep, Lenka Čepová

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This article is focused on the thermal spray coating machining issue. Those are irreplaceable in many areas of nowadays industrial branches such as aerospace industry, mostly thanks to their excellent qualities in production and also in renovation of machinery parts. The principals of thermal spraying and elementary diversification are described in introduction. Plasma coating method of composite materials -cermets- is described more thoroughly. The second part describes thermal spray coating machining and grinding in detail. This part contains suggestion of appropriate grinding tool and assessment of cutting conditions used for grinding a given part. Conclusion describes a problem which occurred while grinding a cermet thermal spray coating with a specially designed grindstone and a way to solve this problem.

Keywords: coating, aerospace, plasma, grinding

Procedia PDF Downloads 555

Authors: Mohamed Sahli, David Bassir, Thierry Barriere, Xavier Roizard

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Predicting the behaviour of the Ti-6Al-4V alloy during the turning operation was very important in the choice of suitable cutting tools and also in the machining strategies. In this study, a 3D model with thermo-mechanical coupling has been proposed to study the influence of cutting parameters and also lubrication on the performance of cutting tools. The constants of the constitutive Johnson-Cook model of Ti-6Al-4V alloy were identified using inverse analysis based on the parameters of the orthogonal cutting process. Then, numerical simulations of the finishing machining operation were developed and experimentally validated for the cylindrical stock removal stage with the finishing cutting tool.

Keywords: titanium turning, cutting tools, FE simulation, chip

Procedia PDF Downloads 173

Authors: Mohamed Abdel-Monem, Gamal Sowilam, Omar Hegazy

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This paper presents a technical assessment of an electric vehicle with two independent rear-wheel motor and an improved traction control system. The electric differential and the control strategy have been implemented to assure that in a straight trajectory, the two rear-wheels run exactly at the same speed, considering the same/different road conditions under the left and right side of the wheels. In case of turning to right/left, the difference between the two rear-wheels speeds assures a vehicle trajectory without sliding, thanks to a harmony between the electric differential and the control strategy. The present article demonstrates a complete model and analysis of a traction control system, considering four different traction scenarios, for two independent rear-wheels motors for electric vehicles. Furthermore, the vehicle model, including wheel dynamics, load forces, electric differential, and control strategy, is designed and verified by using MATLAB/Simulink environment.

Keywords: electric vehicle, energy saving, multi-motor, electric differential, simulation and control

Procedia PDF Downloads 351

Authors: Muhammad Jamil, Ning He, Aqib Mashood Khan, Munish Kumar Gupta

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Ti-6Al-4V has numerous applications in the medical, automobile, and aerospace industries due to corrosion resistivity, structural stability, and chemical inertness to most fluids at room temperature. These peculiar characteristics are beneficial for their application and present formidable challenges during machining. Machining of Ti-6Al-4V produces an elevated cutting temperature above 1000oC at dry conditions. This accelerates tool wear and reduces product quality. Therefore, there is always a need to employ sustainable/effective coolant/lubricant when machining such alloy. In this study, Finite Element Modeling (FEM) and experimental analysis when cutting Ti-6Al-4V under a distinctly developed dry ice mixed hybrid lubri-coolant are presented. This study aims to model the milling process of Ti-6Al-4V under a proposed novel hybrid lubri-coolant using different cutting speeds and feed per tooth DEFORM® software package was used to conduct the FEM and the numerical model was experimentally validated. A comparison of experimental and simulation results showed a maximum error of no more than 6% for all experimental conditions. In a nutshell, it can be said that the proposed model is effective in predicting the machining temperature precisely.

Keywords: friction coefficient, heat transfer, finite element modeling (FEM), milling Ti-6Al-4V

Procedia PDF Downloads 58

Authors: Kechnit Djamel, Ammarri Abdelhadi, Raphael Tshimang, Mark Trrig

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One of the most important aspects of monitoring rivers is navigation. The variation of discharge in the river generally produces a change in available draft for a vessel, particularly in the low flow season, which can impact the navigable water path, especially when the water depth is less than the normal one, which allows safe navigation for boats. The water depth is related to the bathymetry of the channel as well as the discharge. For a seasonal update of the navigation maps, a daily discharge value is required. Many novel approaches based on earth observation and remote sensing have been investigated for large rivers. However, it should be noted that most of these approaches are not currently able to directly estimate river discharge. This paper discusses the application of remote sensing tools using the analysis of the reflectance value of MODIS imagery and is combined with field measurements for the estimation of discharge. This approach is applied in the lower reach of the Congo River (Pool Malebo) for the period between 2019 and 2021. The correlation obtained between the observed discharge observed in the gauging station and the reflectance ratio time series is 0.81. In this context, a Discharge Reflectance Model (DRM) was developed to express discharge as a function of reflectance. This model introduces a non-contact method that allows discharge monitoring using earth observation. DRM was validated by field measurements using ADCP, in different sections on the Pool Malebo, over two different periods (dry and wet seasons), as well as by the observed discharge in the gauging station. The observed error between the estimated and measured discharge values ranges from 1 to 8% for the ADCP and from (1% to 11%) for the gauging station. The study of the uncertainties will give us the possibility to judge the robustness of the DRM.

Keywords: discharge monitoring, navigation, MODIS, empiric, ADCP, Congo River

Procedia PDF Downloads 92

Authors: Mostafa Dastori, Sirus Mohammadi

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While plug-in electric vehicles (PEVs) potentially have the capability to fulfill the energy storage needs of the electric grid, the degradation on the battery during this operation makes it less preferable by the auto manufacturers and consumers. On the other hand, the on-board chargers can also supply energy storage system applications such as reactive power compensation, voltage regulation, and power factor correction without the need of engaging the battery with the grid and thereby preserving its lifetime. It presents the design motives of single-phase on-board chargers in detail and makes a classification of the chargers based on their future vehicle-to-grid usage. The pros and cons of each different ac–dc topology are discussed to shed light on their suit- ability for reactive power support. This paper also presents and analyzes the differences between charging-only operation and capacitive reactive power operation that results in increased demand from the dc-link capacitor (more charge/discharge cycles and in- creased second harmonic ripple current). Moreover, battery state of charge is spared from losses during reactive power operation, but converter output power must be limited below its rated power rating to have the same stress on the dc-link capacitor.

Keywords: energy storage system, battery unit, cost, optimal sizing, plug-in electric vehicles (PEVs), smart grid

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Authors: B. Rajesh Kamath, J. Sundara Rajan, M. K. Veeraiah, M. Z. Kurian

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Insulation performance of a gas insulated system is severely affected by particle contaminants. These metallic particles adversely affect the characteristics of insulating system. These particles can produce surface charges due to partial discharge activities. These particles which are free to move enhance the local electric fields. This paper deals with the influence of conducting particle placed in a co-axial duct on the discharge characteristics of gas mixtures. Co-axial duct placed in a high pressure chamber is used for the purpose. A gas pressure of 0.1, 0.2 and 0.3 MPa have been considered with a 10:90 SF₆ and N₂ gas mixtures. The 2D and 3D histograms of clean duct and duct with copper particle are discussed in this paper.

Keywords: coaxial duct, gas insulated system, gas mixtures, metallic particle, partial discharges, histograms

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Authors: Song-Chol Pak, Yong-Jun Kim, Hak- Chol Choe, Yong-Son Choe

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We converted the coal-water-oil slurry (CWOS) into an alternative fuel (AF) for internal combustion engines by high-voltage discharge (HVD) and dielectric barrier discharge (DBD) plasmas. After its treatments, the CWOS had the average coal size reduced from 12.95 to 8.26㎛, improved dispersibility, fewer deposits, and calorific value enhanced by 35%. The effects of some parameters were analyzed on the conversion of CWOS to AF, and the AF was characterized. The plasma-treated CWOS is similar to other liquid fuels in rheological properties and calorific value. It is therefore concluded that it can be directly employed in internal combustion engines with a little design modification. The suggested method may be an alternative way of converting CWOS to AF without any dispersant or stabilizer.

Keywords: coal-water-oil slurry, high-voltage discharge, dielectric barrier discharge, plasma treatment, alternative fuel

Procedia PDF Downloads 24

Authors: Zhang Tianping, Jia Yanhui, Li Juan, Yang Le, Yang Hao, Yang Wei, Sun Xiaojing, Shi Kai, Li Xingda, Sun Yunkui

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Lanzhou Institute of Physics (LIP) is the major supplier of electric propulsion subsystems for Chinese satellite platforms. The development statuses of these electric propulsion subsystems were summarized including the LIPS-200 ion electric propulsion subsystem (IEPS) for DFH-3B platform, the LIPS-300 IEPS for DFH-5 and DFH-4SP platform, the LIPS-200+ IEPS for DFH-4E platform and near-earth asteroid exploration spacecraft, the LIPS-100 IEPS for small satellite platform, the LHT-100 hall electric propulsion subsystem (HEPS) for flight test on XY-2 satellite, the LHT-140 HEPS for large LEO spacecraft, the LIPS-400 IEPS for deep space exploration mission and other EPS for other Chinese spacecraft.

Keywords: ion electric propulsion, hall electric propulsion, satellite platform, LIP

Procedia PDF Downloads 731

Authors: M. N. Osman Zahid, K. Case, D. Watts

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This paper reports an advanced approach in the application of CNC machining for rapid manufacturing processes (CNC-RM). The aim of this study is to improve the quality of machined parts by introducing different cutting tools during finishing operations. As the cutting is performed in different directions, the surfaces presented on part can be classified into several categories. Therefore, suitable cutting tools are assigned to machine particular surfaces and to improve the quality. Experimental studies have been carried out by fabricating several parts based on the suggested approach. The results provide further support for implementing this approach in rapid machining processes.

Keywords: CNC machining, end mill tool, finishing operation, rapid manufacturing

Procedia PDF Downloads 346

Authors: Tanmaya Pradhan, K. Midhun, M. Joy Thomas

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Increasing the shelf life and improving the quality are important objectives for the success of packaged liquid food industry. One of the methods by which this can be achieved is by deactivating the micro-organisms present in the liquid food through pasteurization. Pasteurization is done by heating, but some serious disadvantages such as the reduction in food quality, flavour, taste, colour, etc. were observed because of heat treatment, which leads to the development of newer methods instead of pasteurization such as treatment using UV radiation, high pressure, nuclear irradiation, pulsed electric field, etc. In recent years the use of the pulsed electric field (PEF) for inactivation of the microbial content in the food is gaining popularity. PEF uses a very high electric field for a short time for the inactivation of microorganisms, for which we require a high voltage pulsed power source. Pulsed power sources used for PEF treatments are usually in the range of 5kV to 50kV. Different pulse shapes are used, such as exponentially decaying and square wave pulses. Exponentially decaying pulses are generated by high power switches with only turn-on capacity and, therefore, discharge the total energy stored in the capacitor bank. These pulses have a sudden onset and, therefore, a high rate of rising but have a very slow decay, which yields extra heat, which is ineffective in microbial inactivation. Square pulses can be produced by an incomplete discharge of a capacitor with the help of a switch having both on/off control or by using a pulse forming network. In this work, a pulsed power-based system is designed with the help of high voltage capacitors and solid-state switches (IGBT) for the inactivation of pathogenic micro-organism in liquid food such as fruit juices. The high voltage generator is based on the Marx generator topology, which can produce variable amplitude, frequency, and pulse width according to the requirements. Liquid food is treated in a chamber where pulsed electric field is produced between stainless steel electrodes using the pulsed output voltage of the supply. Preliminary bacterial inactivation tests were performed by subjecting orange juice inoculated with Escherichia Coli bacteria. With the help of the developed pulsed power source and the chamber, the inoculated orange has been PEF treated. The voltage was varied to get a peak electric field up to 15kV/cm. For a total treatment time of 200µs, a 30% reduction in the bacterial count has been observed. The detailed results and analysis will be presented in the final paper.

Keywords: Escherichia coli bacteria, high voltage generator, microbial inactivation, pulsed electric field, pulsed forming line, solid-state switch

Procedia PDF Downloads 184

Authors: B. Varaprasad, C. Srinivasa Rao

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In the manufacturing sector, hard turning has emerged as vital machining process for cutting hardened steels. Besides many advantages of hard turning operation, one has to implement to achieve close tolerances in terms of surface finish, high product quality, reduced machining time, low operating cost and environmentally friendly characteristics. In the present study, three-dimensional CAE (Computer Aided Engineering) based simulation of  hard turning by using commercial software DEFORM 3D has been compared to experimental results of  stresses, temperatures and tool forces in machining of AISI D3 steel using mixed Ceramic inserts (CC6050). In the present analysis, orthogonal cutting models are proposed, considering several processing parameters such as cutting speed, feed, and depth of cut. An exhaustive friction modeling at the tool-work interfaces is carried out. Work material flow around the cutting edge is carefully modeled with adaptive re-meshing simulation capability. In process simulations, feed rate and cutting speed are constant (i.e.,. 0.075 mm/rev and 155 m/min), and analysis is focused on stresses, forces, and temperatures during machining. Close agreement is observed between CAE simulation and experimental values.

Keywords: hard turning, computer aided engineering, computational machining, finite element method

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Authors: Courret Gilles, Pidoux Damien

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Considering that sunshine is the ultimate reference in lighting, we have examined the spectral correlation between a series of electric light sources and sunlight. As the latter is marked by fluctuations, we have taken two spectra of reference: on the one hand, the CIE daylight standard illuminant, and on the other hand, the global illumination by the clear sky with the sun at 30° above the horizon. We determined the coefficients of correlation between the spectra filtered by the sensitivity of the CIE standard observer for photopic vision. We also calculated the luminous efficiency of the radiation in order to compare the ideal energy performances as well as the CIE color indexes Ra, Ra14, and Rf, since the choice of a light source requires a trade-off between color rendering and luminous efficiency. The benchmarking includes the most commonly used bulbs, various white LED (Lighting Emitting Diode) of warm white or cold white types, incandescent halogen as well as two HID lamps (High-Intensity Discharge) and two plasma lamps of different types, a solar simulator and a new version of the sulfur lamp. The latter obtains the best correlation, whether in comparison with the solar spectrum or that of the standard illuminant.

Keywords: electric light sources, plasma lamp, daylighting, sunlight, spectral correlation

Procedia PDF Downloads 185

Authors: Theena Thayalan, K. N. Ramesh Babu

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Machining induced residual stress (RS) is one of the most important surface integrity parameters that characterize the near surface layer of a mechanical component, which plays a crucial role in controlling the performance, especially its fatigue life. Since experimental determination of RS is expensive and time consuming, it would be of great benefit if they could be predicted. In such case, it would be possible to select the cutting parameters required to produce a favorable RS profile. In the present study, an effort has been made to develop a 'two dimensional finite element model (FEM)' to simulate orthogonal cutting process and to predict surface and sub-surface RS using the commercial FEA software DEFORM-2D. The developed finite element model has been validated through experimental investigation of RS. In the experimentation, the orthogonal cutting tests were carried out on AISI 4340 by varying the cutting speed (VC) and uncut chip thickness (f) at three levels and the surface & sub-surface RS has been measured using XRD and Electro polishing techniques. The comparison showed that the RS obtained using developed numerical model is in reasonable agreement with that of experimental data.

Keywords: FEM, machining, residual stress, XRF

Procedia PDF Downloads 348

Authors: Abdallah M. Abdelkawy, Tarek M. El Hossainya, I. El Mahallawib

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Recently, significant achievements have been made in development and manufacturing of nano-dispersed metal matrix nanocomposites (MMNCs). They gain their importance due to their high strength to weight ratio. The machining problems of these new materials are less widely investigated, thus this work focuses on machining of them. Aluminum-Silicon (A356)/ MMNC dispersed with alumina (Al2O3) is important in many applications include engine blocks. The final finish process of this application depends heavily on machining. The most important machining parameter studied includes: cutting force and surface roughness. Experimental trails are performed on the number of special samples of MMNC (with different Al2O3%) where the relation between Al2O3% and cutting speed, feed rate and cutting depth with cutting force and surface roughness were studied. The data obtained were statistically analyzed using Analysis of variance (ANOVA) to define the significant factors on both cutting force and surface roughness and their level of confident. Response Surface Methodology (RSM) is used to build a model relating cutting conditions and Al2O3% to the cutting force and surface roughness. The results have shown that feed and depth of cut have the major contribution on the cutting force and the surface roughness followed by cutting speed and nano-percent in MMNCs.

Keywords: machinability, cutting force, surface roughness, Ra, RSM, ANOVA, MMNCs

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Authors: Javier A. Dominguez Caballero, Graeme A. Manson, Matthew B. Marshall

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Cutting tools with ceramic inserts are often used in the process of machining many types of superalloy, mainly due to their high strength and thermal resistance. Nevertheless, during the cutting process, the plastic flow wear generated in these inserts enhances and propagates cracks due to high temperature and high mechanical stress. This leads to a very variable failure of the cutting tool. This article explores the relationship between the continuous wear that ceramic SiAlON (solid solutions based on the Si3N4 structure) inserts experience during a high-speed machining process and the evolution of sparks created during the same process. These sparks were analysed through pictures of the cutting process recorded using an SLR camera. Features relating to the intensity and area of the cutting sparks were extracted from the individual pictures using image processing techniques. These features were then related to the ceramic insert’s crater wear area.

Keywords: ceramic cutting tools, high speed machining, image processing, tool condition monitoring, tool wear

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Authors: Ahmed A. D. Sarhan, M. Sayuti, M. Hamdi

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Due to rapid consumption of world's fossil fuel resources and impracticality of large-scale application and production of renewable energy, the significance of energy efficiency improvement of current available energy modes has been widely realized by both industry and academia. In the CNC machining field, the key solution for this issue is by increasing the effectiveness of the existing lubrication systems as it could reduce the power required to overcome the friction component in machining process. For more improvement, introducing the nanolubrication could produce much less power consumption as the rolling action of billions units of nanoparticle in the tool chip interface could reduce the cutting forces significantly. In this research, the possibility of using carbon onion nanolubrication with DLC cutting tool is investigated to reduce the machining power consumption. Carbon onion nanolubrication has been successfully developed with high tribology performance and mixed with ordinary mineral oil. The proper sonification method is used to provide a way to mix and suspend the particles thoroughly and efficiently. Furthermore, Diamond-Like Carbon (DLC) cutting tool is used and expected to play significant role in reducing friction and cutting forces and increasing abrasion resistance. The results showed significant reduction of the cutting force and the working power compared with the other conditions of using carbon black and normal lubrication systems.

Keywords: carbon onion, nanolubrication, machining power consumption, DLC cutting tool

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Authors: Joseph Chen, N. Hundal

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Conventional machining is a form of subtractive manufacturing, in which a collection of material-working processes utilizing power-driven machine tools are used to remove undesired material to achieve a desired geometry. This paper presents an approach for comparison between turning center and vertical machining center by optimization of cutting parameters at cylindrical workpieces leading to minimum surface roughness by using taguchi methodology. Aluminum alloy was taken to conduct experiments due to its unique high strength-weight ratio that is maintained at elevated temperatures and their exceptional corrosion resistance. During testing, the effects of the cutting parameters on the surface roughness were investigated. Additionally, by using taguchi methodology for each of the cutting parameters (spindle speed, depth of cut, insert diameter, and feed rate) minimum surface roughness for the process of turn-milling was determined according to the cutting parameters. A confirmation experiment demonstrates the effectiveness of taguchi method.

Keywords: surface roughness, Taguchi parameter design, turning center, turn-milling operations, vertical machining center

Procedia PDF Downloads 329

Authors: Hoai Nam Huynh, Edouard Rivière-Lorphèvre, Olivier Verlinden

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Manufacturing technologies are becoming continuously more diversified over the years. The increasing use of robots for various applications such as assembling, painting, welding has also affected the field of machining. Machining robots can deal with larger workspaces than conventional machine-tools at a lower cost and thus represent a very promising alternative for machining applications. Furthermore, their inherent structure ensures them a great flexibility of motion to reach any location on the workpiece with the desired orientation. Nevertheless, machining robots suffer from a lack of stiffness at their joints restricting their use to applications involving low cutting forces especially finishing operations. Vibratory instabilities may also happen while machining and deteriorate the precision leading to scrap parts. Some researchers are therefore concerned with the identification of optimal parameters in robotic machining. This paper continues the development of a virtual robotic machining simulator in order to find optimized cutting parameters in terms of depth of cut or feed per tooth for example. The simulation environment combines an in-house milling routine (DyStaMill) achieving the computation of cutting forces and material removal with an in-house multibody library (EasyDyn) which is used to build a dynamic model of a 3-DOF planar robot with flexible links. The position of the robot end-effector submitted to milling forces is controlled through an inverse kinematics scheme while controlling the position of its joints separately. Each joint is actuated through a servomotor for which the transfer function has been computed in order to tune the corresponding controller. The output results feature the evolution of the cutting forces when the robot structure is deformable or not and the tracking errors of the end-effector. Illustrations of the resulting machined surfaces are also presented. The consideration of the links flexibility has highlighted an increase of the cutting forces magnitude. This proof of concept will aim to enrich the database of results in robotic machining for potential improvements in production.

Keywords: control, milling, multibody, robotic, simulation

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Authors: Clémence Royer, Stéphane Mazouffre

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Nowadays, electric propulsion systems play a crucial role in space exploration missions due to their high specific impulse and long operational life. The Hall thrusters are one of the most mature EP technologies. It is a gridless ion thruster that has proved reliable and high-performance for decades in various space missions. Operation of HT relies on electron emissions through a cathode placed outside a hollow dielectric channel that includes an anode at the back. Negatively charged particles are trapped in a magnetic field and efficiently slow down. By collisions, the electron cloud ionizes xenon atoms. A large electric field is generated in the axial direction due to the low electron transverse mobility in the region of a strong magnetic field. Positive particles are pulled out of the chamber at high velocity and are neutralized directly at the exhaust area. This phenomenon leads to the acceleration of the spacecraft system at a high specific impulse. While HT’s architecture and operating principle are relatively simple, the physics behind thrust is complex and still partly unknown. Current and voltage oscillations, as well as electron properties, have been captured over a 30 mn time period after ignition. The observed low-frequency oscillations exhibited specific frequency ranges, amplitudes, and stability patterns. Correlations between the oscillations and plasma characteristics we analyzed. The impact of these instabilities on thruster performance, including thrust efficiency, has been evaluated as well. Moreover, strategies for mitigating and controlling these instabilities have been developed, such as filtering. In this contribution, in addition to presenting a summary of the results obtained in the transient regime, we will present and discuss recent advances in Hall thruster plasma discharge filtering and control.

Keywords: electric propulsion, Hall Thruster, plasma diagnostics, low-frequency oscillations

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Authors: Himanshu J. Bahirat, Apoorva S. Janawlekar

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Plasma actuators are essential for aerodynamic flow separation control due to their lack of mechanical parts, lightweight, and high response frequency, which have numerous applications in hypersonic or supersonic aircraft. The working of these actuators is based on the formation of a low-temperature plasma between a pair of parallel electrodes by the application of a high-voltage AC signal across the electrodes, after which air molecules from the air surrounding the electrodes are ionized and accelerated through the electric field. The high-frequency operation is required in dielectric discharge barriers to ensure plasma stability. To carry out flow separation control in a hypersonic flow, the optimal design and construction of a power supply to generate dielectric barrier discharges is carried out in this paper. In this paper, it is aspired to construct a simplified circuit topology to emulate the dielectric barrier discharge and study its various frequency responses. The power supply can generate high voltage pulses up to 20kV at the repetitive frequency range of 20-50kHz with an input power of 500W. The power supply has been designed to be short circuit proof and can endure variable plasma load conditions. Its general outline is to charge a capacitor through a half-bridge converter and then later discharge it through a step-up transformer at a high frequency in order to generate high voltage pulses. After simulating the circuit, the PCB design and, eventually, lab tests are carried out to study its effectiveness in controlling flow separation.

Keywords: aircraft propulsion, dielectric barrier discharge, flow separation control, power source

Procedia PDF Downloads 128

Authors: Aldan A. Sapargaliyev, Yerbol A. Sapargaliyev

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Since the invention, the electric machine (EM) can be defined as oEM – one-vector electric machine, as it works due to one-vector inductive coupling with use of one-vector electromagnet. The disadvantages of oEM are large size and limited efficiency at low and medium power applications. This paper describes multi-vector electric machine (mEM) based on multi-vector inductive coupling, which is characterized by the increased surface area of ​​the inductive coupling per EM volume, with a reduced share of inefficient and energy-consuming part of the winding, in comparison with oEM’s. Particularly, it is considered, calculated and compared the performance of three different electrical motors and their power at the same volumes and rotor frequencies. It is also presented the result of calculation of correlation between power density and volume for oEM and mEM. The method of multi-vector inductive coupling enables mEM to possess 1.5-4.0 greater density of power per volume and significantly higher efficiency, in comparison with today’s oEM, especially in low and medium power applications. mEM has distinct advantages, when used in transport vehicles such as electric cars and aircrafts.

Keywords: electric machine, electric motor, electromagnet, efficiency of electric motor

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Authors: Vinay Patil, Swapnil Kekade, Ashish Supare, Vinayak Pawar, Shital Jadhav, Rajkumar Singh

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In recent days, bainitic steel is used in automobile and non-automobile sectors due to its high strength. Bainitic steel is difficult to machine because of its high hardness, hence in this paper machinability of bainitic steel is studied by using Taguchi design of experiments (DOE) approach. Convectional turning experiments were done by using L16 orthogonal array for three input parameters viz. cutting speed, depth of cut and feed. The Taguchi method is applied to study the performance characteristics of machining parameters with surface roughness (Ra), cutting force and tool wear rate. By using Taguchi analysis, optimized process parameters for best surface finish and minimum cutting forces were analyzed.

Keywords: conventional turning, Taguchi method, S/N ratio, bainitic steel machining

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Authors: Yanhui Jia, Ning Guo, Juan Li, Yunkui Sun, Wei Yang, Tianping Zhang, Lin Ma, Wei Meng, Hai Geng

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The current statuses of lifetime test of LaB6 hollow cathode at the Lanzhou institute of physics (LIP), China, was described. 5A LaB6 hollow cathode was designed for LIPS-200 40mN Xenon ion thruster and it could be used for LHT-100 80 mN Hall thruster, too. Life test of the discharge and neutralizer modes of LHC-5 hollow cathode were stared in October 2011, and cumulative operation time reached 17,300 and 16,100 hours in April 2015, respectively. The life of cathode was designed more than 11,000 hours. Parameters of discharge and key structure dimensions were monitored in different stage of life test indicated that cathodes were health enough. The test will continue until the cathode cannot work or operation parameter is not in normally. The result of the endurance test of cathode demonstrated that the LaB6 hollow cathode is satisfied for the required of thruster in life and performance.

Keywords: LaB6, hollow cathode, thruster, lifetime test, electric propulsion

Procedia PDF Downloads 606

Authors: Joy Chiu, Colin Hemez, Emma Ryan, Jia Sun, Robert Dubrow, Michael Pascucilla

Abstract:

The popularity of recreational boating is on the rise in the United States, which raises numerous national-level challenges in the management of air and water pollution, aquatic habitat destruction, and waterway access. The need to control sewage discharge from recreational vessels underlies all of these challenges. The release of raw human waste into aquatic environments can lead to eutrophication and algal blooms; can increase human exposure to pathogenic viruses, bacteria, and parasites; can financially impact commercial shellfish harvest/fisheries and marine bathing areas; and can negatively affect access to recreational and/or commercial waterways to the detriment of local economies. Because of the damage that unregulated sewage discharge can do to environments and human health/marine life, recreational vessels in the United States are required by law to 'pump-out' sewage from their holding tanks into sewage treatment systems in all designated 'no discharge areas'. Many pump-out boats, which transfer waste out of recreational vessels, are operated and maintained using funds allocated through the Federal Clean Vessel Act (CVA). The East Shore District Health Department of Branford, Connecticut is protecting this estuary by pioneering the design and construction of the first-in-the-nation zero-emissions, the solar-electric pump-out boat of its size to replace one of its older traditional gasoline-powered models through a Connecticut Department of Energy and Environmental Protection CVA Grant. This study, conducted in collaboration with the East Shore District Health Department, the Connecticut Department of Energy and Environmental Protection, States Organization for Boating Access and Connecticut’s CVA program coordinators, had two aims: (1) To perform a national assessment of pump-out boat programs, supplemented by a limited international assessment, to establish best pump-out boat practices (regardless of how the boat is powered); and (2) to estimate the cost, greenhouse gas emissions, and environmental and public health impacts of solar-electric versus traditional gasoline-powered pump-out boats. A national survey was conducted of all CVA-funded pump-out program managers and selected pump-out boat operators to gauge best practices; costs associated with gasoline-powered pump-out boat operation and management; and the regional, cultural, and policy-related issues that might arise from the adoption of solar-electric pump-out boat technology. We also conducted life-cycle analyses of gasoline-powered and solar-electric pump-out boats to compare their greenhouse gas emissions; production of air, soil and water pollution; and impacts on human health. This work comprises the most comprehensive study into pump-out boating practices in the United States to date, in which information obtained at local, state, national, and international levels is synthesized. This study aims to enable CVA programs to make informed recommendations for sustainable pump-out boating practices and identifies the challenges and opportunities that remain for the wide adoption of solar-electric pump-out boat technology.

Keywords: pump-out boat, marine water, solar-electric, zero emissions

Procedia PDF Downloads 128

Authors: Mathew Saxon A, Aneeh Rajan, Sajeev P

Abstract:

Many fluid flow applications employ different types of orifices to control the flow rate or to reduce the pressure. Discharge coefficients generally vary from 0.6 to 0.95 depending on the type of the orifice. The tabulated value of discharge coefficients of various types of orifices available can be used in most common applications. The upstream and downstream flow condition of an orifice is hardly considered while choosing the discharge coefficient of an orifice. But literature shows that the discharge coefficient can be affected by the presence of cross flow. Cross flow is defined as the condition wherein; a fluid is injected nearly perpendicular to a flowing fluid. Most researchers have worked on water being injected into a cross-flow of water. The present work deals with water to gas systems in which water is injected in a normal direction into a flowing stream of gas. The test article used in the current work is called thermal regulator, which is used in a liquid rocket engine to reduce the temperature of hot gas tapped from the gas generator by injecting water into the hot gas so that a cooler gas can be supplied to the turbine. In a thermal regulator, water is injected through an orifice in a normal direction into the hot gas stream. But the injection orifice had been calibrated under backpressure by maintaining a stagnant gas medium at the downstream. The motivation of the present study aroused due to the observation of a lower Cd of the orifice in flight compared to the calibrated Cd. A systematic experimental investigation is carried out in this paper to study the effect of cross-flow on the discharge coefficient of an orifice in water to a gas system. The study reveals that there is an appreciable reduction in the discharge coefficient with cross flow compared to that without cross flow. It is found that the discharge coefficient greatly depends on the ratio of momentum of water injected to the momentum of the gas cross flow. The effective discharge coefficient of different orifices was normalized using the discharge coefficient without cross-flow and it is observed that normalized curves of effective discharge coefficient of different orifices with momentum ratio collapsing into a single curve. Further, an equation is formulated using the test data to predict the effective discharge coefficient with cross flow using the calibrated Cd value without cross flow.

Keywords: cross flow, discharge coefficient, orifice, momentum ratio

Procedia PDF Downloads 143

Authors: Emiliano Lustrissimi, Bonifacio Bianco, Sebastiano Caravaggi, Antonio Rosato

Abstract:

A mathematical framework has been designed to enhance the configuration of an end-of-production-line (EOL) test bench. This system can be used to assess the performance of electric motors or axles intended for electric vehicles. The model has been developed to predict the behaviour of EOL test benches and electric motors/axles under various boundary conditions, eliminating the need for extensive physical testing and reducing the corresponding power consumption. The suggested model is versatile, capable of being utilized across various types of electric motors or axles, and adaptable to accommodate varying power ratings of electric motors or axles. The maximum performance to be guaranteed by the EMs according to the car maker's specifications are taken as inputs in the model. Then, the required performance of each main EOL test bench component is calculated, and the corresponding systems available on the market are selected based on manufacturers’ catalogues. In this study, an EOL test bench has been designed according to the proposed model outputs for testing a low-power (about 22 kW) electric axle. The performance of the designed EOL test bench has been measured and used to validate the proposed model and assess both the consistency of the constraints as well as the accuracy of predictions in terms of electric demands. The comparison between experimental and predicted data exhibited a reasonable agreement, allowing to demonstrate that, despite some discrepancies, the model gives an accurate representation of the EOL test benches' performance.

Keywords: electric motors, electric vehicles, end-of-production-line test bench, mathematical model, field tests

Procedia PDF Downloads 51

Authors: Fawad Azeem

Abstract:

This paper deals with the comparative analysis of Karachi Electric before and after privatization. Technical as well as financial analysis has been done based on the available KE’s stats for last decade. Karachi Electric has evolved as a better entity in terms of its financial and technical achievements. On the other hand, human resources have been seriously affected due to mass firing of employees from the organizations. Study and analysis show that transparent and unbiased privatization practices on institutions like KE that were in serious trouble can upsurge the standards of the institution. Further, for the betterment of the social circle privatization must not affect the employment opportunities.

Keywords: Karachi Electric, power, energy, privatization

Procedia PDF Downloads 354