Search results for: fuel tube

Authors: Won Mok. Choi, Tae Su. Kwon, Hyun Sung. Jung, Jin Sung. Kim

Abstract:

The aim of this paper is to confirm the effect of key design parameters, the punch radius and punch angle, on rupture of the expansion tube using a finite element analysis with a ductile damage model. The results of the finite element analysis indicated that the expansion ratio of the tube was mainly affected by the radius of the punch. However, the rupture was more affected by the punch angle than the radius of the punch. The existence of a specific punch angle, at which rupture did not occur, even if the radius of the punch was increased, was found.

Keywords: Expansion tube, Ductile damage, Shear failure, Stress triaxiality.

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Authors: Mudjiastuti Handajani

Abstract:

The national economy development affects the vehicle ownership which ultimately increases fuel consumption. The rise of the vehicle ownership is dominated by the increasing number of motorcycles. This research aims to analyze and identify the characteristics of fuel consumption, the city transportation system, and to analyze the relationship and the effect of the city transportation system on the fuel consumption. A multivariable analysis is used in this study. The data analysis techniques include: a Multivariate Multivariable Analysis by using the R software. More than 84% of fuel on Java is consumed in metropolitan and large cities. The city transportation system variables that strongly effect the fuel consumption are population, public vehicles, private vehicles and private bus. This method can be developed to control the fuel consumption by considering the urban transport system and city tipology. The effect can reducing subsidy on the fuel consumption, increasing state economic.

Keywords: city, consumption, fuel, transportation

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Authors: M. Ali, K. Alam, E. Ohioma

Abstract:

This paper presents a numerical investigation on the behavior of fiber reinforced polymer composite tubes (FRP) under thermomechanical coupled loading using finite element software ABAQUS and a special add-on subroutine, CZone. Three cases were explored; pure mechanical loading, pure thermal loading, and coupled thermomechanical loading. The failure index (Tsai-Wu) under all three loading cases was assessed for all plies in the tube walls. The simulation results under pure mechanical loading showed that composite tube failed at a tensile load of 3.1 kN. However, with the superposition of thermal load on mechanical load on the composite tube, the failure index of the previously failed plies in tube walls reduced significantly causing the tube to fail at 6 kN. This showed 93% improvement in the load carrying capacity of the composite tube in present study. The increase in load carrying capacity was attributed to the stress effects of the coefficients of thermal expansion (CTE) on the laminate as well as the inter-lamina stresses induced due to the composite stack layup.

Keywords: Thermal, mechanical, composites, square tubes.

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Authors: Ei Ei Moe, Zaw Min Aung, Kyawt Khin

Abstract:

This paper puts forward one kind of air-fuel ratio control method with PI controller. With the help of MATLAB/SIMULINK software, the mathematical model of air-fuel ratio control system for distributorless CNG engine is constructed. The objective is to maintain cylinder-to-cylinder air-fuel ratio at a prescribed set point, determined primarily by the state of the Three- Way-Catalyst (TWC), so that the pollutants in the exhaust are removed with the highest efficiency. The concurrent control of airfuel under transient conditions could be implemented by Proportional and Integral (PI) controller. The simulation result indicates that the control methods can easily eliminate the air/fuel maldistribution and maintain the air/fuel ratio at the stochiometry within minimum engine events.

Keywords: Distributorless CNG Engine, Mathematical Modelof Air-fuel control, MATLAB/SIMULINK, PI controller

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Authors: Gürol Önal, Kevser Dincer

Abstract:

In this experimental study, performance of a counter flow Ranque-Hilsch vortex tube (RHVT) with threads cut on its inner surface was investigated experimentally (pitch is 1 and 2 mm). The inner diameter of the vortex tube used was D=9 mm and the ratio of the tube’s length to diameter was L/D=12. The experimental system was a thermodynamic open system. Flow was controlled by a valve on the hot outlet side, where the valve was changed from a nearly closed position to its nearly open position. Fraction of cold flow (ξ) = 0.1-0.9, was determined under 300 and 350 kPa pressurized air. All experimental data were compared with each other, the maximum heating performance of the RHVT system was found to be 38.2 oC and the maximum cooling performance of the RHVT in this study was found to be -30.9 oC at pitch 1 mm.

Keywords: Ranque-Hilsch vortex tube, heating, cooling, temperature separation.

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Authors: Giuliano Raimondo, Jörg Wangemann, Peer Drechsel

Abstract:

In systems development involving Fuel Cells generators, it is important to have from an early stage of the project a dynamic model for the electrical behavior of the stack to be shared between involved development parties. It allows independent and early design and tests of fuel cell related power electronic. This paper presents an empirical Fuel Cell system model derived from characterization tests on a real system. Moreover, it is illustrated how the obtained model is used to build and validate a real-time Fuel Cell system emulator which is used for aerospace electrical integration testing activities.

Keywords: Fuel cell dynamics, real time simulation, fuel cell, modelling, testing.

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Authors: Samir J. Deshmukh, Lalit B. Bhuyar, Shashank B. Thakre

Abstract:

Partial combustion of biomass in the gasifier generates producer gas that can be used for heating purposes and as supplementary or sole fuel in internal combustion engines. In this study, the virgin biomass obtained from hingan shell is used as the feedstock for gasifier to generate producer gas. The gasifier-engine system is operated on diesel and on esters of vegetable oil of hingan in liquid fuel mode operation and then on liquid fuel and producer gas combination in dual fuel mode operation. The performance and emission characteristics of the CI engine is analyzed by running the engine in liquid fuel mode operation and in dual fuel mode operation at different load conditions with respect to maximum diesel savings in the dual fuel mode operation. It was observed that specific energy consumption in the dual fuel mode of operation is found to be in the higher side at all load conditions. The brake thermal efficiency of the engine using diesel or hingan oil methyl ester (HOME) is higher than that of dual fuel mode operation. A diesel replacement in the tune of 60% in dual fuel mode is possible with the use of hingan shell producer gas. The emissions parameters such CO, HC, NOx, CO2 and smoke are higher in the case of dual fuel mode of operation as compared to that of liquid fuel mode.

Keywords: Esters, performance, producer gas, vegetable oil.

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Authors: Fathollah Ommi, Golnaz Pourabedin, Koros Nekofa

Abstract:

In recent years fuel cell vehicles are rapidly appearing all over the globe. In less than 10 years, fuel cell vehicles have gone from mere research novelties to operating prototypes and demonstration models. At the same time, government and industry in development countries have teamed up to invest billions of dollars in partnerships intended to commercialize fuel cell vehicles within the early years of the 21st century. The purpose of this study is evaluation of model and performance of fuel cell hybrid electric vehicle in different drive cycles. A fuel cell system model developed in this work is a semi-experimental model that allows users to use the theory and experimental relationships in a fuel cell system. The model can be used as part of a complex fuel cell vehicle model in advanced vehicle simulator (ADVISOR). This work reveals that the fuel consumption and energy efficiency vary in different drive cycles. Arising acceleration and speed in a drive cycle leads to Fuel consumption increase. In addition, energy losses in drive cycle relates to fuel cell system power request. Parasitic power in different parts of fuel cell system will increase when power request increases. Finally, most of energy losses in drive cycle occur in fuel cell system because of producing a lot of energy by fuel cell stack.

Keywords: Drive cycle, Energy efficiency, energy consumption, Fuel cell system.

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Authors: Ashutosh Kumar Rai, Naveen Kumar, Bhupendra Singh Chauhan

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Increased energy demand and the concern about environment friendly technology, renewable bio-fuels are better alternative to petroleum products. In the present study linseed oil was used as alternative source for diesel engine fuel and the results were compared with baseline data of neat diesel. Performance parameters such as brake thermal efficiency (BTE) and brake specific fuel consumption (BSFC) and emissions parameters such as CO, unburned hydro carbon (UBHC), NOx, CO2 and exhaust temperature were compared. BTE of the engine was lower and BSFC was higher when the engine was fueled with Linseed oil compared to diesel fuel. Emission characteristics are better than diesel fuel. NOx formation by using linseed oil during the experiment was lower than diesel fuel. Linseed oil is non edible oil, so it can be used as an extender of diesel fuel energy source for small and medium energy needs.

Keywords: Bio-fuel, exhaust emission, linseed oil, triglyceride.

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Authors: Elfetori F. Abdewi

Abstract:

This paper presents the effect of corrugation profile geometry on the crushing behavior, energy absorption, failure mechanism, and failure mode of woven roving glass fibre/epoxy laminated composite tube. Experimental investigations were carried out on composite tubes with three different profile shapes: sinusoidal, triangular and trapezoidal. The tubes were subjected to lateral compressive loading. On the addition to a radial corrugated composite tube, cylindrical composite tube, were fabricated and tested under the same condition in order to know the effect of corrugation geometry. Typical histories of their deformation are presented. Behavior of tubes as regards the peak crushing load, energy absorbed and mode of crushing has been discussed. The results show that the behavior of the tube under lateral compression load is influenced by the geometry of the tube itself.

Keywords: Corrugated composite specimens, Energy absorption, Lateral crushing.

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Authors: Geun-Il Park, Jae-Won Lee, Dou-Youn Lee, Jung-Won Lee, Kwang-Wook Kim, Kee-Chan Song

Abstract:

Thermochemcial characteristics of powder fabricated using oxidation treatment of spent PWR fuel and SIMFUEL were evaluated for recycling of spent fuel such as DUPIC process. Especially, the influence of spent fuel burn-ups on the powder fabrication characteristics was experimentally evaluated, ranging from 27,300 to 65,000 MWd/tU. Densities of powder manufactured from an oxidation, OREOX and the milling processes at the same process conditions were compared as a function of the fuel burn-ups respectively. Also, based on chemical analysis results, homogeneity of fissile elements in oxidized powder was confirmed.

Keywords: Spent PWR fuel, DUPIC, Oxidation, OREOX, Powder, Chemical analysis

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Authors: Elham Zamiri

Abstract:

In this research, we have focused on numeral simulation of a fuel rod in order to examine distribution of heat temperature in components of fuel rod by Fluent software by providing steady state, single phase fluid flow, frequency heat flux in a fuel rod in nuclear reactor to numeral simulation. Results of examining different layers of a fuel rod consist of fuel layer, gap, pod, and fluid cooling flow, also examining thermal properties and fluids such as heat transition rate and pressure drop. The obtained results through analytical method and results of other sources have been compared and have appropriate correspondence. Results show that using heavy water as cooling fluid along with few layers of gas and pod have the ability of reducing the temperature from above 300 ^◦C to 70 ^◦C. This investigation is developable for any geometry and material used in the nuclear reactor.

Keywords: Nuclear fuel fission, numberal simulation, fuel rod, reactor, fluent software.

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Authors: W. Witchayanuwat, S. Kheawhom

Abstract:

In this work, we experimentally study heat transfer from exhaust particulate air of detergent spray drying tower to water by using coiled tube heat exchanger. Water flows in the coiled tubes, where air loaded with detergent particles of 43 micrometers in diameter flows within the shell. Four coiled tubes with different coil pitches are used in a counter-current flow configuration. We investigate heat transfer coefficients of inside and outside the heat transfer surfaces through 400 experiments. The correlations between Nusselt number and Reynolds number, Prandtl number, mass flow rate of particulates to mass flow rate of air ratio and coiled tube pitch parameter are proposed. The correlations procured can be used to predicted heat transfer between tube and shell of the heat exchanger.

Keywords: Shell and coiled tube heat exchanger, Spray drying tower, Heat transfer coefficients.

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Authors: Dimitrie Marinceu

Abstract:

The newest Canadian Used Fuel Container (UFC)- (called also “Mark II”) modifies the design approach for its Assembly Robotic Cell (ARC) in the Canadian Used (Nuclear) Fuel Packing Plant (UFPP). Some of the robotic design solutions are presented in this paper. The design indicates that robots and manipulators are expected to be used in the Canadian UFPP. As normally, the UFPP design will incorporate redundancy of all equipment to allow expedient recovery from any postulated upset conditions. Overall, this paper suggests that robot usage will have a significant positive impact on nuclear safety, quality, productivity, and reliability.

Keywords: Used fuel packing plant, robotic assembly cell, used fuel container, deep geological repository.

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Authors: Kanhu Charan Bhuyan, Subhransu Padhee, Rajesh Kumar Patjoshi, Kamalakanta Mahapatra

Abstract:

Fuel cell is an emerging technology in the field of renewable energy sources which has the capacity to replace conventional energy generation sources. Fuel cell utilizes hydrogen energy to produce electricity. The electricity generated by the fuel cell can’t be directly used for a specific application as it needs proper power conditioning. Moreover, the output power fluctuates with different operating conditions. To get a stable output power at an economic rate, power conditioning circuit is essential for fuel cell. This paper implements a two-staged power conditioning unit for fuel cell based distributed generation using hysteresis current control technique.

Keywords: Fuel cell, power conditioning unit, hysteresis control.

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Authors: Yi Liu

Abstract:

In this paper, computational fluid dynamics (CFD) is utilized to characterize a prototype biolistic delivery system, the biomedical device based on the contoured-shock-tube design (CST), with the aim at investigating shocks induced flow instabilities within the contoured shock tube. The shock/interface interactions, the growth of perturbation at an interface between two fluids of different density are interrogated. The key features of the gas dynamics and gas-particle interaction are discussed

Keywords: Simulation, Shock wave, Particle, Interface, Supersonic, Richtmyer-Meshkov Instability

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Authors: Ayudhia P. Gusti, Semin

Abstract:

It is known that total operating cost of a vessel is dominated by the cost of fuel consumption. How to reduce the fuel cost of ship so that the operational costs of fuel can be minimized is the question that arises. As the basis of these kinds of problem, sailing speed determination is an important factor to be considered by a shipping company. Optimal speed determination will give a significant influence on the route and berth schedule of ships, which also affect vessel operating costs. The purpose of this paper is to clarify some important issues about ship speed optimization. Sailing speed, displacement, sailing time, and specific fuel consumption were obtained from shipping log data to be further analyzed for modeling the speed optimization. The presented speed optimization model is expected to affect the fuel consumption and to reduce the cost of fuel consumption.

Keywords: Maritime transportation, reducing fuel, shipping log data, speed optimization.

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Authors: E. H. N. Gashti, M. Malaska, K. Kujala

Abstract:

The thermo-mechanical behaviour of concrete energy pile foundations with different single and double U-tube shapes incorporated was analysed using the Comsol Multi-physics package. For the analysis, a 3D numerical model in real scale of the concrete pile and surrounding soil was simulated regarding actual operation of ground heat exchangers (GHE) and the surrounding ambient temperature. Based on initial ground temperature profile measured in situ, tube inlet temperature was considered to range from 6oC to 0oC (during the contraction process) over a 30-day period. Extra thermal stresses and deformations were calculated during the simulations and differences arising from the use of two different systems (single-tube and double-tube) were analysed. The results revealed no significant difference for extra thermal stresses at the centre of the pile in either system. However, displacements over the pile length were found to be up to 1.5-fold higher in the double-tube system than the singletube system.

Keywords: Concrete Energy Piles, Stresses, Displacements, Thermo-mechanical behaviour, Soil-structure interactions.

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Authors: Oluwaseyi O. Taiwo, Adeolu A. Adediran, Abayomi A. Akinwande, Frank C. Okoyeh

Abstract:

The use of fuel fired crucible furnace is essential in the foundries of developing countries owing to the luxury of electricity. Fuel fired crucible furnace are commonly used in recycling, casting, research and training activities in tertiary institutions, therefore, several attempts are being made to improve the performance and service life of fuel fired crucible. The current study reviews the sequential stages involved in the designs and fabrication of fuel fired crucible furnace which include; design, material selection, modelling and simulation as well as performance evaluation. The study shows that selecting appropriate materials for the different units in the fabrication process is important to the efficiency and service life of fuel fired crucible furnaces. Also, efficiency and performance of fuel fired furnaces are independent of cost of fabrication and their capacity. The importance of modelling and simulation tools in the fabrication process are identified while their non-frequent usage in several works is observed. The need to widen performance evaluations in further studies beyond efficiency determination to give a more detailed assessment of fuel fired crucible furnaces is also observed.

Keywords: Crucible furnace, furnace design, fabrication, fuel.

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Authors: Suhadiyana Hanapi, Alhassan Salami Tijani, W. A. N Wan Mohamed

Abstract:

In this paper, a prototype PEM fuel cell vehicle integrated with a 1 kW air-blowing proton exchange membrane fuel cell (PEMFC) stack as a main power sources has been developed for a lightweight cruising vehicle. The test vehicle is equipped with a PEM fuel cell system that provides electric power to a brushed DC motor. This vehicle was designed to compete with industrial lightweight vehicle with the target of consuming least amount of energy and high performance. Individual variations in driving style have a significant impact on vehicle energy efficiency and it is well established from the literature. The primary aim of this study was to assesses the power and fuel consumption of a hydrogen fuel cell vehicle operating at three difference driving technique (i.e. 25 km/h constant speed, 22-28 km/h speed range, 20-30 km/h speed range). The goal is to develop the best driving strategy to maximize performance and minimize fuel consumption for the vehicle system. The relationship between power demand and hydrogen consumption has also been discussed. All the techniques can be evaluated and compared on broadly similar terms. Automatic intelligent controller for driving prototype fuel cell vehicle on different obstacle while maintaining all systems at maximum efficiency was used. The result showed that 25 km/h constant speed was identified for optimal driving with less fuel consumption.

Keywords: Prototype fuel cell electric vehicles, energy efficient, control/driving technique, fuel economy.

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Authors: Ping Yuan, Mu-Sheng Chiang, Syu-Fang Liu, Shih-Bin Wang, Ming-Jun Kuo

Abstract:

This study investigates the electrical performance of a planar solid oxide fuel cell unit with cross-flow configuration when the fuel utilization gets higher and the fuel inlet flow are non-uniform. A software package in this study solves two-dimensional, simultaneous, partial differential equations of mass, energy, and electro-chemistry, without considering stack direction variation. The results show that the fuel utilization increases with a decrease in the molar flow rate, and the average current density decreases when the molar flow rate drops. In addition, non-uniform Pattern A will induce more severe happening of non-reaction area in the corner of the fuel exit and the air inlet. This non-reaction area deteriorates the average current density and then deteriorates the electrical performance to –7%.

Keywords: Performance, Solid oxide fuel cell, non-uniform, fuelutilization

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Authors: N. Tahouni, M. Gholami, M. H. Panjeshahi

Abstract:

Gas flaring is one of the most GHG emitting sources in the oil and gas industries. It is also a major way for wasting such an energy that could be better utilized and even generates revenue. Minimize flaring is an effective approach for reducing GHG emissions and also conserving energy in flaring systems. Integrating waste and flared gases into the fuel gas networks (FGN) of refineries is an efficient tool. A fuel gas network collects fuel gases from various source streams and mixes them in an optimal manner, and supplies them to different fuel sinks such as furnaces, boilers, turbines, etc. In this article we use fuel gas network model proposed by Hasan et al. as a base model and modify some of its features and add constraints on emission pollution by gas flaring to reduce GHG emissions as possible. Results for a refinery case study showed that integration of flare gas stream with waste and natural gas streams to construct an optimal FGN can significantly reduce total annualized cost and flaring emissions.

Keywords: Flaring, Fuel gas network, GHG emissions.

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Authors: Yendiyarov Sergei, Zobnin Boris, Petrushenko Sergei

Abstract:

Usually, the solid-fuel flow of an iron ore sinter plant consists of different types of the solid-fuels, which differ from each other. Information about the composition of the solid-fuel flow usually comes every 8-24 hours. It can be clearly seen that this information cannot be used to control the sintering process in real time. Due to this, we propose an expert system which uses indirect measurements from the process in order to obtain the composition of the solid-fuel flow by solving an optimization task. Then this information can be used to control the sintering process. The proposed technique can be successfully used to improve sinter quality and reduce the amount of solid-fuel used by the process.

Keywords: sintering process, particle swarm optimization, optimal control, expert system, solid-fuel

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Authors: Imane Khalil, Quinn Pratt

Abstract:

In a nuclear reactor, an array of fuel rods containing stacked uranium dioxide pellets clad with zircalloy is the heat source for a thermodynamic cycle of energy conversion from heat to electricity. After fuel is used in a nuclear reactor, the assemblies are stored underwater in a spent nuclear fuel pool at the nuclear power plant while heat generation and radioactive decay rates decrease before it is placed in packages for dry storage or transportation. A computational model of a Boiling Water Reactor spent fuel assembly is modeled using FLUENT, the computational fluid dynamics package. Heat transfer simulations were performed on the two-dimensional 9x9 spent fuel assembly to predict the maximum cladding temperature for different input to the FLUENT model. Uncertainty quantification is used to predict the heat transfer and the maximum temperature profile inside the assembly.

Keywords: Spent nuclear fuel, conduction, heat transfer, uncertainty quantification.

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Authors: Sagar Pramodrao Kadu, Rajendra H. Sarda

Abstract:

The concerns about clean environment and high oil prices driving forces for the research on alternative fuels. The research efforts directed towards improving the performance of C.I engines using vegetable oil as fuel. The paper deals results of performance of a four stroke, single cylinder C.I. engine by preheated neat Karanja oil is done from 30 o C to 100 o C. The performance of the engine was studied for a speed range between 1500 to 4000 rpm, with the engine operated under full load conditions. The performance parameters considered for comparing are brake specific fuel consumption, thermal efficiency, brake power, Nox emission of the engine. The engine offers lower thermal efficiency when it is powered by preheated neat Karanja oil at higher speed. The power developed and Nox emission increase with the increase in the fuel inlet temperature and the specific fuel consumption is higher than diesel fuel operation at all elevated fuel inlet temperature.

Keywords: Alternative fuel, Compression ignition engine, neatKaranja oil, preheating.

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Authors: David Lávicka

Abstract:

This paper looks into detailed investigation of thermal-hydraulic characteristics of the flow field in a fuel rod model, especially near the spacer. The area investigate represents a source of information on the velocity flow field, vortex, and on the amount of heat transfer into the coolant all of which are critical for the design and improvement of the fuel rod in nuclear power plants. The flow field investigation uses three-dimensional Computational Fluid Dynamics (CFD) with the Reynolds stresses turbulence model (RSM). The fuel rod model incorporates a vertical annular channel where three different shapes of spacers are used; each spacer shape is addressed individually. These spacers are mutually compared in consideration of heat transfer capabilities between the coolant and the fuel rod model. The results are complemented with the calculated heat transfer coefficient in the location of the spacer and along the stainless-steel pipe.

Keywords: CFD, fuel rod model, heat transfer, spacer

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Authors: Mohd Hazwan bin Yusof, Hiroshi Katanoda

Abstract:

In order to clarify the structure of the cold flow discharged from the vortex tube (VT), the pressure of the cold flow was measured, and a simple flow visualization technique using a 0.75mm-diameter needle and an oily paint is made to study the reverse flow at the cold exit. It is clear that a negative pressure and positive pressure region exist at a certain pressure and cold fraction area, and that a reverse flow is observed in the negative pressure region.

Keywords: Flow visualization, Pressure measurement, Reverse flow, Vortex tube.

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Authors: E. Elgendy, J. Schmidt

Abstract:

Drop-in of R-22 alternatives in refrigeration and air conditioning systems requires a redesign of system components to improve system performance and reliability with the alternative refrigerants. The present paper aims at design adiabatic capillary tubes for R-22 alternatives such as R-417A, R-422D and R-438A. A theoretical model has been developed and validated with the available experimental data from literature for R-22 over a wide range of both operating and geometrical parameters. Predicted lengths of adiabatic capillary tube are compared with the lengths of the capillary tube needed under similar experimental conditions and majority of predictions are found to be within 4.4% of the experimental data. Hence, the model has been applied for R-417A, R- 422D and R-438A and capillary tube selection charts and correlations have been computed. Finally a comparison between the selected refrigerants and R-22 has been introduced and the results showed that R-438A is the closest one to R-22.

Keywords: Adiabatic flow, Capillary tube, R-22 alternatives, Rating charts, Modelling.

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Authors: Nilam S. Octaviani, Semin

Abstract:

The diesel engine is an internal combustion engine that uses compressed air to combust. The diesel engines are widely used in the world because it has the most excellent combustion efficiency than other types of internal combustion engine.  However, the exhaust emissions of it produce pollutants that are harmful to human health and the environment. Therefore, natural gas used as an alternative fuel using on compression ignition engine to respond those environment issues. This paper aims to discuss the comparison of the technical characteristics and exhaust gases emission from conventional diesel engine and dual fuel diesel engine. According to the study, the dual fuel engine applications have a lower compression pressure and has longer ignition delay compared with normal diesel mode. The engine power is decreased at dual fuel mode. However, the exhaust gases emission on dual fuel engine significantly reduce the nitrogen oxide (NOx), carbon dioxide (CO₂) and particular metter (PM) emissions.

Keywords: Diesel engine, dual fuel engine, emissions, technical characteristics.

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Authors: P. Meethum, C. Suvanjumrat

Abstract:

Many aluminum motorcycle parts produced by a high pressure die casting. Some parts such as fuel caps were a thin and complex shape. This part risked for porosities and blisters on surface if it only depended on an experience of mold makers for mold design. This research attempted to use CAST-DESIGNER software simulated the high pressure die casting process with the same process parameters of a motorcycle fuel cap production. The simulated results were compared with fuel cap products and expressed the same porosity and blister locations on cap surface. An average of absolute difference of simulated results was obtained 0.094 mm when compared the simulated porosity and blister defect sizes on the fuel cap surfaces with the experimental micro photography. This comparison confirmed an accuracy of software and will use the setting parameters to improve fuel cap molds in the further work.

Keywords: Aluminum, die casting, fuel cap, motorcycle.

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