Search results for: rotating collector

Authors: M. Israil Hossain, T. P. Tiwari, Ashrafuzzaman Gulandaz, Nusrat Jahan

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Two-wheel tractor (power tiller) is a common tillage tool in Bangladesh agriculture for easy access in fragmented land with affordable price of small farmers. Traditional maize sheller needs to be carried from place to place by hooking with two-wheel tractor (2WT) and set up again for shelling operation which takes longer time for preparation of maize shelling. The mobile maize sheller eliminates the transportation problem and can start shelling operation instantly any place as it is attached together with 2WT. It is counterclockwise rotating cylinder, axial flow type sheller, and grain separated with a frictional force between spike tooth and concave. The maize sheller is attached with nuts and bolts in front of the engine base of 2WT. The operating power of the sheller comes from the fly wheel of the engine of the tractor through ‘V” belt pulley arrangement. The average shelling capacity of the mobile sheller is 2.0 t/hr, broken kernel 2.2%, and shelling efficiency 97%. The average maize shelling cost is Tk. 0.22/kg and traditional custom hire rate is Tk.1.0/kg, respectively (1 US$=Tk.78.0). The service provider of the 2WT can transport the mobile maize sheller long distance in operator’s seating position. The manufacturers started the fabrication of mobile maize sheller. This mobile maize sheller is also compatible for the other countries where 2WT is available for farming operation.

Keywords: Cost effective, mobile maize sheller, maize shelling capacity, small farmers, two-wheel tractor.

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Authors: Michael G. Pantelyat

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Fundamental basics of pure and applied research in the area of magneto-thermo-mechanical numerical analysis and design of innovative electromagnetic devices (modern induction heaters, novel thermoelastic actuators, rotating electrical machines, induction cookers, electrophysical devices) are elaborated. Thus, mathematical models of magneto-thermo-mechanical processes in electromagnetic devices taking into account main interactions of interrelated phenomena are developed. In addition, graphical representation of coupled (multiphysics) phenomena under consideration is proposed. Besides, numerical techniques for nonlinear problems solution are developed. On this base, effective numerical algorithms for solution of actual problems of practical interest are proposed, validated and implemented in applied 2D and 3D computer codes developed. Many applied problems of practical interest regarding modern electrical engineering devices are numerically solved. Investigations of the influences of various interrelated physical phenomena (temperature dependences of material properties, thermal radiation, conditions of convective heat transfer, contact phenomena, etc.) on the accuracy of the electromagnetic, thermal and structural analyses are conducted. Important practical recommendations on the choice of rational structures, materials and operation modes of electromagnetic devices under consideration are proposed and implemented in industry.

Keywords: Electromagnetic devices, multiphysics, numerical analysis, simulation and design.

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Authors: Krishnaiah Arkanti, Ramulu Malothu

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The experiments have been conducted to study the mechanical properties of commercially pure copper processing at room temperature by severe plastic deformation using equal channel angular extrusion (ECAE) through a die of 90^oangle up to 3 passes by route B_C i.e. rotating the sample in the same direction by 90^o after each pass. ECAE is used to produce from existing coarse grains to ultra-fine, equiaxed grains structure with high angle grain boundaries in submicron level by introducing a large amount of shear strain in the presence of hydrostatic pressure into the material without changing billet shape or dimension. Mechanical testing plays an important role in evaluating fundamental properties of engineering materials as well as in developing new materials and in controlling the quality of materials for use in design and construction. Yield stress, ultimate tensile stress and ductility are structure sensitive properties and vary with the structure of the material. Microhardness and tensile tests were carried out to evaluate the hardness, strength and ductility of the ECAE processed materials. The results reveal that the strength and hardness of commercially pure copper samples improved significantly without losing much ductility after each pass.

Keywords: Equal Channel Angular Extrusion, Severe Plastic Deformation, Copper, Mechanical Properties.

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Authors: Consalva J. Msigwa, Beda J. Kundy, Bakari M. M. Mwinyiwiwa

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In this paper the reference current for Voltage Source Converter (VSC) of the Shunt Active Power Filter (SAPF) is generated using Synchronous Reference Frame method, incorporating the PI controller with anti-windup scheme. The proposed method improves the harmonic filtering by compensating the winding up phenomenon caused by the integral term of the PI controller. Using Reference Frame Transformation, the current is transformed from om a - b - c stationery frame to rotating 0 - d - q frame. Using the PI controller, the current in the 0 - d - q frame is controlled to get the desired reference signal. A controller with integral action combined with an actuator that becomes saturated can give some undesirable effects. If the control error is so large that the integrator saturates the actuator, the feedback path becomes ineffective because the actuator will remain saturated even if the process output changes. The integrator being an unstable system may then integrate to a very large value, the phenomenon known as integrator windup. Implementing the integrator anti-windup circuit turns off the integrator action when the actuator saturates, hence improving the performance of the SAPF and dynamically compensating harmonics in the power network. In this paper the system performance is examined with Shunt Active Power Filter simulation model.

Keywords: Phase Locked Loop (PLL), Voltage SourceConverter (VSC), Shunt Active Power Filter (SAPF), PI, Pulse WidthModulation (PWM).

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Authors: Ahmet Taşan, Süha Tirkeş, Yavuz Öztürk, Zafer Bingül

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Friction stir welding (FSW) is a joining process in the solid state, which eliminates problems associated with the material melting and solidification, such as cracks, residual stresses and distortions generated during conventional welding. Among the most important advantages of FSW are; easy automation, less distortion, lower residual stress and good mechanical properties in the joining region. FSW is a recent approach to metal joining and although originally intended for aluminum alloys, it is investigated in a variety of metallic materials. The basic concept of FSW is a rotating tool, made of non-consumable material, specially designed with a geometry consisting of a pin and a recess (shoulder). This tool is inserted as spinning on its axis at the adjoining edges of two sheets or plates to be joined and then it travels along the joining path line. The tool rotation axis defines an angle of inclination with which the components to be welded. This angle is used for receiving the material to be processed at the tool base and to promote the gradual forge effect imposed by the shoulder during the passage of the tool. This prevents the material plastic flow at the tool lateral, ensuring weld closure on the back of the pin. In this study, two 4 mm Kevlar^® plates which were produced with the Kevlar^® fabrics, are analyzed with COMSOL Multiphysics in order to investigate the weldability via FSW. Thereafter, some experimental investigation is done with an appropriate workbench in order to compare them with the analysis results.

Keywords: Analytical modeling, composite materials welding, friction stir welding, heat generation.

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Authors: Julio C. Gómez-Mancilla, Luis M. Palacios-Pineda, Yunuén López-Grijalba

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A new mechanism responsible for structural life consumption due to resonant fatigue in turbine blades, or vanes, is presented and explained. A rotating blade or vane in a gas turbine can change its contour due to erosion and/or material build up, in any of these instances, the surface pressure distribution occurring on the suction and pressure sides of blades-vanes can suffer substantial modification of their pressure and temperatures envelopes and flow characteristics. Meanwhile, the relative rotation between the blade and duct vane while the pressurized gas flows and the consequent wake crossings, will induce a fluctuating thrust force or lift that will excite the blade. An actual totally used up set of vane-blade components in a HP turbine power stage in a gas turbine is analyzed. The blade suffered some material erosion mostly at the trailing edge provoking a peculiar surface pressure envelope which evolved as the relative position between the vane and the blade passed in front of each other. Interestingly preliminary modal analysis for this eroded blade indicates several natural frequencies within the aeromechanic power spectrum, moreover, the highest frequency component is 94% of one natural frequency indicating near resonant condition. Independently of other simultaneously occurring fatigue cycles (such as thermal, centrifugal stresses).

Keywords: Aeromechanic induced vibration, potential flowinteraction, turbine unsteady flow, rotor/stator interaction, turbinevane-blade aerodynamic interaction, airfoil clocking

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Authors: Alireza Rasekh, Peter Sergeant, Jan Vierendeels

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This paper copes with the numerical simulation for convective heat transfer in the stator disk of an axial flux permanent magnet (AFPM) electrical machine. Overheating is one of the main issues in the design of AFMPs, which mainly occurs in the stator disk, so that it needs to be prevented. A rotor-stator configuration with 16 magnets at the periphery of the rotor is considered. Air is allowed to flow through openings in the rotor disk and channels being formed between the magnets and in the gap region between the magnets and the stator surface. The rotating channels between the magnets act as a driving force for the air flow. The significant non-dimensional parameters are the rotational Reynolds number, the gap size ratio, the magnet thickness ratio, and the magnet angle ratio. The goal is to find correlations for the Nusselt number on the stator disk according to these non-dimensional numbers. Therefore, CFD simulations have been performed with the multiple reference frame (MRF) technique to model the rotary motion of the rotor and the flow around and inside the machine. A minimization method is introduced by a pattern-search algorithm to find the appropriate values of the reference temperature. It is found that the correlations are fast, robust and is capable of predicting the stator heat transfer with a good accuracy. The results reveal that the magnet angle ratio diminishes the stator heat transfer, whereas the rotational Reynolds number and the magnet thickness ratio improve the convective heat transfer. On the other hand, there a certain gap size ratio at which the stator heat transfer reaches a maximum.

Keywords: Axial flux permanent magnet, CFD, magnet parameters, stator heat transfer.

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Authors: P. G. Siddheshwar, T. N. Sakshath

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In the paper we make linear and non-linear stability analyses of Rayleigh-Bénard convection of a Newtonian nanoliquid in a rotating medium (called as Rayleigh-Bénard-Taylor convection). Rigid-rigid isothermal boundaries are considered for investigation. Khanafer-Vafai-Lightstone single phase model is used for studying instabilities in nanoliquids. Various thermophysical properties of nanoliquid are obtained using phenomenological laws and mixture theory. The eigen boundary value problem is solved for the Rayleigh number using an analytical method by considering trigonometric eigen functions. We observe that the critical nanoliquid Rayleigh number is less than that of the base liquid. Thus the onset of convection is advanced due to the addition of nanoparticles. So, increase in volume fraction leads to advanced onset and thereby increase in heat transport. The amplitudes of convective modes required for estimating the heat transport are determined analytically. The tri-modal standard Lorenz model is derived for the steady state assuming small scale convective motions. The effect of rotation on the onset of convection and on heat transport is investigated and depicted graphically. It is observed that the onset of convection is delayed due to rotation and hence leads to decrease in heat transport. Hence, rotation has a stabilizing effect on the system. This is due to the fact that the energy of the system is used to create the component V. We observe that the amount of heat transport is less in the case of rigid-rigid isothermal boundaries compared to free-free isothermal boundaries.

Keywords: Nanoliquid, rigid-rigid, rotation, single-phase.

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Authors: S. Ziaran, M. Musil, M. Cekan, O. Chlebo

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The paper analyzes the response of buildings and industrially structures on seismic waves (low frequency mechanical vibration) generated by blasting operations. The principles of seismic analysis can be applied for different kinds of excitation such as: earthquakes, wind, explosions, random excitation from local transportation, periodic excitation from large rotating and/or machines with reciprocating motion, metal forming processes such as forging, shearing and stamping, chemical reactions, construction and earth moving work, and other strong deterministic and random energy sources caused by human activities. The article deals with the response of seismic, low frequency, mechanical vibrations generated by nearby blasting operations on a residential home. The goal was to determine the fundamental natural frequencies of the measured structure; therefore it is important to determine the resonant frequencies to design a suitable modal damping. The article also analyzes the package of seismic waves generated by blasting (Primary waves – P-waves and Secondary waves S-waves) and investigated the transfer regions. For the detection of seismic waves resulting from an explosion, the Fast Fourier Transform (FFT) and modal analysis, in the frequency domain, is used and the signal was acquired and analyzed also in the time domain. In the conclusions the measured results of seismic waves caused by blasting in a nearby quarry and its effect on a nearby structure (house) is analyzed. The response on the house, including the fundamental natural frequency and possible fatigue damage is also assessed.

Keywords: Building structure, seismic waves, spectral analysis, structural response.

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Authors: Ahmed Aljudaya, Derek Ingham, Lin Ma, Kevin Hughes, Mohammed Pourkashanian

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Researchers, power companies, and state politicians have given concentrated solar power (CSP) much attention due to its capacity to generate large amounts of electricity whereas overcoming the intermittent nature of solar resources. The Linear Fresnel Reflector (LFR) is a well-known CSP technology type for being inexpensive, having a low land use factor, and suffering from low optical efficiency. The LFR was considered a cost-effective alternative option to the Parabolic Trough Collector (PTC) because of its simplistic design, and this often outweighs its lower efficiency. The LFR power plants commercially generate steam directly and indirectly in order to produce electricity with high technical efficiency and lower its costs. The purpose of this important analysis is to compare the annual performance of the Direct Steam Generation (DSG) and Indirect Steam Generation (ISG) of LFR power plants using molten salt and other different Heat Transfer Fluids (HTF) to investigate their technical and economic effects. A 50 MWe solar-only system is examined as a case study for both steam production methods in extreme weather conditions. In addition, a parametric analysis is carried out to determine the optimal solar field size that provides the lowest Levelized Cost of Electricity (LCOE) while achieving the highest technical performance. As a result of optimizing the optimum solar field size, the solar multiple (SM) is found to be between 1.2 – 1.5 in order to achieve as low as 9 Cent/KWh for the DSG of the LFR. In addition, the power plant is capable of producing around 141 GWh annually and up to 36% of the capacity factor, whereas the ISG produces less energy at a higher cost. The optimization results show that the DSG’s performance overcomes the ISG in producing around 3% more annual energy, 2% lower LCOE, and 28% less capital cost.

Keywords: Concentrated Solar Power, Levelized cost of electricity, Linear Fresnel reflectors, Steam generation.

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Authors: Omid Ghasemalizadeh, Mohammad Reza Mirzaee, Hossein Sadeghi, Mohammad Taghi Ahmadian

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There are lots of different ways to find the natural frequencies of a rotating system. One of the most effective methods which is used because of its precision and correctness is the application of the transfer matrix. By use of this method the entire continuous system is subdivided and the corresponding differential equation can be stated in matrix form. So to analyze shaft that is this paper issue the rotor is divided as several elements along the shaft which each one has its own mass and moment of inertia, which this work would create possibility of defining the named matrix. By Choosing more elements number, the size of matrix would become larger and as a result more accurate answers would be earned. In this paper the dynamics of a rotor-bearing system is analyzed, considering the gyroscopic effect. To increase the accuracy of modeling the thickness of the disk and bearings is also taken into account which would cause more complicated matrix to be solved. Entering these parameters to our modeling would change the results completely that these differences are shown in the results. As said upper, to define transfer matrix to reach the natural frequencies of probed system, introducing some elements would be one of the requirements. For the boundary condition of these elements, bearings at the end of the shaft are modeled as equivalent spring and dampers for the discretized system. Also, continuous model is used for the shaft in the system. By above considerations and using transfer matrix, exact results are taken from the calculations. Results Show that, by increasing thickness of the bearing the amplitude of vibration would decrease, but obviously the stiffness of the shaft and the natural frequencies of the system would accompany growth. Consequently it is easily understood that ignoring the influences of bearing and disk thicknesses would results not real answers.

Keywords: Rotor System, Disk and Bearing Thickness, Transfer Matrix, Amplitude.

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Authors: Daohong Yang, Xiang Zhang, Wanting Zhou, Lei Li

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Visual Simultaneous Localization and Mapping (VSLAM) is a technology that gathers information about the surrounding environment to ascertain its own position and create a map. It is widely used in computer vision, robotics, and various other fields. Many visual SLAM systems, such as OBSLAM3, utilize a constant velocity motion model. The utilization of this model facilitates the determination of the initial pose of the current frame, thereby enhancing the efficiency and precision of feature matching. However, it is often difficult to satisfy the constant velocity motion model in actual situations. This can result in a significant deviation between the obtained initial pose and the true value, leading to errors in nonlinear optimization results. Therefore, this paper proposes a motion model based on acceleration that can be applied to most SLAM systems. To provide a more accurate description of the camera pose acceleration, we separate the pose transformation matrix into its rotation matrix and translation vector components. The rotation matrix is now represented by a rotation vector. We assume that, over a short period, the changes in rotating angular velocity and translation vector remain constant. Based on this assumption, the initial pose of the current frame is estimated. In addition, the error of the constant velocity model is analyzed theoretically. Finally, we apply our proposed approach to the ORBSLAM3 system and evaluate two sets of sequences from the TUM datasets. The results show that our proposed method has a more accurate initial pose estimation, resulting in an improvement of 6.61% and 6.46% in the accuracy of the ORBSLAM3 system on the two test sequences, respectively.

Keywords: Error estimation, constant acceleration motion model, pose estimation, visual SLAM.

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Authors: Ismail Abubakar, Hamid Mehrabi, Reg Morton

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Currently, extensive signal analysis is performed in order to evaluate structural health of turbomachinery blades. This approach is affected by constraints of time and the availability of qualified personnel. Thus, new approaches to blade dynamics identification that provide faster and more accurate results are sought after. Generally, modal analysis is employed in acquiring dynamic properties of a vibrating turbomachinery blade and is widely adopted in condition monitoring of blades. The analysis provides useful information on the different modes of vibration and natural frequencies by exploring different shapes that can be taken up during vibration since all mode shapes have their corresponding natural frequencies. Experimental modal testing and finite element analysis are the traditional methods used to evaluate mode shapes with limited application to real live scenario to facilitate a robust condition monitoring scheme. For a real time mode shape evaluation, rapid evaluation and low computational cost is required and traditional techniques are unsuitable. In this study, artificial neural network is developed to evaluate the mode shape of a lab scale rotating blade assembly by using result from finite element modal analysis as training data. The network performance evaluation shows that artificial neural network (ANN) is capable of mapping the correlation between natural frequencies and mode shapes. This is achieved without the need of extensive signal analysis. The approach offers advantage from the perspective that the network is able to classify mode shapes and can be employed in real time including simplicity in implementation and accuracy of the prediction. The work paves the way for further development of robust condition monitoring system that incorporates real time mode shape evaluation.

Keywords: Modal analysis, artificial neural network, mode shape, natural frequencies, pattern recognition.

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Authors: Mohammad Syed Ali Molla, Mohammed Azim, Mohammad Esharuzzaman

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Centrifugal-casting machine is used in manufacturing special machine components like multi-layer journal bearing used in all internal combustion engine, steam, gas turbine and air craft turboengine where isotropic properties and high precisions are desired. Moreover, this machine can be used in manufacturing thin wall hightech machine components like cylinder liners and piston rings of IC engine and other machine parts like sleeves, and bushes. Heavy-duty machine component like railway wheel can also be prepared by centrifugal casting. A lot of technological developments are required in casting process for production of good casted machine body and machine parts. Usually defects like blowholes, surface roughness, chilled surface etc. are found in sand casted machine parts. But these can be removed by centrifugal casting machine using rotating metallic die. Moreover, die rotation, its temperature control, and good pouring practice can contribute to the quality of casting because of the fact that the soundness of a casting in large part depends upon how the metal enters into the mold or dies and solidifies. Poor pouring practice leads to variety of casting defects such as temperature loss, low quality casting, excessive turbulence, over pouring etc. Besides these, handling of molten metal is very unsecured and dangerous for the workers. In order to get rid of all these problems, the need of an automatic pouring device arises. In this research work, a robot assisted pouring device and a centrifugal casting machine are designed, developed constructed and tested experimentally which are found to work satisfactorily. The robot assisted pouring device is further modified and developed for using it in actual metal casting process. Lot of settings and tests are required to control the system and ultimately it can be used in automation of centrifugal casting machine to produce high-tech machine parts with desired precision.

Keywords: Casting, cylinder liners, journal bearing, robot.

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Authors: Walid A. M. Ghoneim, Hamdy A. Ashour, Asmaa E. Abdo

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In this paper, linear analysis of a Switched Reluctance Generator (SRG) model is applied on the most common configurations (4/2, 6/4 and 8/6) for both conventional short-pitched and fully-pitched designs, in order to determine the optimum stator/rotor pole angles at which the maximum output voltage is generated per unit excitation current. This study is focused on SRG analysis and design as a proposed solution for renewable energy applications, such as wind energy conversion systems. The world’s potential to develop the renewable energy technologies through dedicated scientific researches was the motive behind this study due to its positive impact on economy and environment. In addition, the problem of rare earth metals (Permanent magnet) caused by mining limitations, banned export by top producers and environment restrictions leads to the unavailability of materials used for rotating machines manufacturing. This challenge gave authors the opportunity to study, analyze and determine the optimum design of the SRG that has the benefit to be free from permanent magnets, rotor windings, with flexible control system and compatible with any application that requires variable-speed operation. In addition, SRG has been proved to be very efficient and reliable in both low-speed or high-speed applications. Linear analysis was performed using MATLAB simulations based on the (Modified generalized matrix approach) of Switched Reluctance Machine (SRM). About 90 different pole angles combinations and excitation patterns were simulated through this study, and the optimum output results for each case were recorded and presented in detail. This procedure has been proved to be applicable for any SRG configuration, dimension and excitation pattern. The delivered results of this study provide evidence for using the 4-phase 8/6 fully pitched SRG as the main optimum configuration for the same machine dimensions at the same angular speed.

Keywords: Generalized matrix approach, linear analysis, renewable applications, switched reluctance generator, SRG.

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Authors: Md Monir Hossain, Anne Staples, Kuya Takami, Tomonari Furukawa

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Tire noise has a significant impact on ride quality and vehicle interior comfort, even at low frequency. Reduction of tire noise is especially important due to strict state and federal environmental regulations. The primary sources of tire noise are the low frequency structure-borne noise and the noise that originates from the release of trapped air between the tire tread and road surface during each revolution of the tire. The frequency response of the tire changes at low and high frequency. At low frequency, the tension and bending moment become dominant, while the internal structure and local deformation become dominant at higher frequencies. Here, we analyze tire response in terms of deformation and rolling velocity at low revolution frequency. An Abaqus FEA finite element model is used to calculate the static and dynamic response of a rolling tire under different rolling conditions. The natural frequencies and mode shapes of a deformed tire are calculated with the FEA package where the subspace-based steady state dynamic analysis calculates dynamic response of tire subjected to harmonic excitation. The analysis was conducted on the dynamic response at the road (contact point of tire and road surface) and side nodes of a static and rolling tire when the tire was excited with 200 N vertical load for a frequency ranging from 20 to 200 Hz. The results show that frequency has little effect on tire deformation up to 80 Hz. But between 80 and 200 Hz, the radial and lateral components of displacement of the road and side nodes exhibited significant oscillation. For the static analysis, the fluctuation was sharp and frequent and decreased with frequency. In contrast, the fluctuation was periodic in nature for the dynamic response of the rolling tire. In addition to the dynamic analysis, a steady state rolling analysis was also performed on the tire traveling at ground velocity with a constant angular motion. The purpose of the computation was to demonstrate the effect of rotating motion on deformation and rolling velocity with respect to a fixed Newtonian reference point. The analysis showed a significant variation in deformation and rolling velocity due to centrifugal and Coriolis acceleration with respect to a fixed Newtonian point on ground.

Keywords: Natural frequency, rotational motion, steady state rolling, subspace-based steady state dynamic analysis.

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Authors: Cheng-Chung Yang, Jr-Ming Miao, Fuh-Lin Lih, Tsung-Lung Liu, Ming-Hui Ho

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The operation performance of a valveless micro-pump is strongly dependent on the shape of connected nozzle/diffuser and Reynolds number. The aims of present work are to compare the performance curves of micropump with the original straight nozzle/diffuser and contoured nozzle/diffuser under different back pressure conditions. The tested valveless micropumps are assembled of five pieces of patterned PMMA plates with hot-embracing technique. The structures of central chamber, the inlet/outlet reservoirs and the connected nozzle/diffuser are fabricated with laser cutting machine. The micropump is actuated with circular-type PZT film embraced on the bottom of central chamber. The deformation of PZT membrane with various input voltages is measured with a displacement laser probe. A simple testing facility is also constructed to evaluate the performance curves for comparison. In order to observe the evaluation of low Reynolds number multiple vortex flow patterns within the micropump during suction and pumping modes, the unsteady, incompressible laminar three-dimensional Reynolds-averaged Navier-Stokes equations are solved. The working fluid is DI water with constant thermo-physical properties. The oscillating behavior of PZT film is modeled with the moving boundary wall in way of UDF program. With the dynamic mesh method, the instants pressure and velocity fields are obtained and discussed.Results indicated that the volume flow rate is not monotony increased with the oscillating frequency of PZT film, regardless of the shapes of nozzle/diffuser. The present micropump can generate the maximum volume flow rate of 13.53 ml/min when the operation frequency is 64Hz and the input voltage is 140 volts. The micropump with contoured nozzle/diffuser can provide 7ml/min flow rate even when the back pressure is up to 400 mm-H2O. CFD results revealed that the flow central chamber was occupied with multiple pairs of counter-rotating vortices during suction and pumping modes. The net volume flow rate over a complete oscillating periodic of PZT

Keywords: valveless micropump、PZT diagraph、contoured nozzle/diffuser、vortex flow.

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Authors: A. Lauvray, F. Poulhaon, P. Michaud, P. Joyot, E. Duc

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Additive Friction Stir Manufacturing, or AFSM, is a new industrial process that follows the emergence of friction-based processes. The AFSM process is a solid-state additive process using the energy produced by the friction at the interface between a rotating non-consumable tool and a substrate. Friction depends on various parameters like axial force, rotation speed or friction coefficient. The feeder material is a metallic rod that flows through a hole in the tool. There is still a lack in understanding of the physical phenomena taking place during the process. This research aims at a better AFSM process understanding and implementation, thanks to numerical simulation and experimental validation performed on a prototype effector. Such an approach is considered a promising way for studying the influence of the process parameters and to finally identify a process window that seems relevant. The deposition of material through the AFSM process takes place in several phases. In chronological order these phases are the docking phase, the dwell time phase, the deposition phase, and the removal phase. The present work focuses on the dwell time phase that enables the temperature rise of the system due to pure friction. An analytic modeling of heat generation based on friction considers as main parameters the rotational speed and the contact pressure. Another parameter considered influential is the friction coefficient assumed to be variable, due to the self-lubrication of the system with the rise in temperature or the materials in contact roughness smoothing over time. This study proposes through a numerical modeling followed by an experimental validation to question the influence of the various input parameters on the dwell time phase. Rotation speed, temperature, spindle torque and axial force are the main monitored parameters during experimentations and serve as reference data for the calibration of the numerical model. This research shows that the geometry of the tool as well as fluctuations of the input parameters like axial force and rotational speed are very influential on the temperature reached and/or the time required to reach the targeted temperature. The main outcome is the prediction of a process window which is a key result for a more efficient process implementation.

Keywords: numerical model, additive manufacturing, frictional heat generation, process

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Authors: Markus Rütten, Olaf Wünsch

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Non-Newtonian fluid properties can change the flow behaviour significantly, its prediction is more difficult when thermal effects come into play. Hence, the focal point of this work is the wake flow behind a heated circular cylinder in the laminar vortex shedding regime for thermo-viscous shear thinning fluids. In the case of isothermal flows of Newtonian fluids the vortex shedding regime is characterised by a distinct Reynolds number and an associated Strouhal number. In the case of thermo-viscous shear thinning fluids the flow regime can significantly change in dependence of the temperature of the viscous wall of the cylinder. The Reynolds number alters locally and, consequentially, the Strouhal number globally. In the present CFD study the temperature dependence of the Reynolds and Strouhal number is investigated for the flow of a Carreau fluid around a heated cylinder. The temperature dependence of the fluid viscosity has been modelled by applying the standard Williams-Landel-Ferry (WLF) equation. In the present simulation campaign thermal boundary conditions have been varied over a wide range in order to derive a relation between dimensionless heat transfer, Reynolds and Strouhal number. Together with the shear thinning due to the high shear rates close to the cylinder wall this leads to a significant decrease of viscosity of three orders of magnitude in the nearfield of the cylinder and a reduction of two orders of magnitude in the wake field. Yet the shear thinning effect is able to change the flow topology: a complex K´arm´an vortex street occurs, also revealing distinct characteristic frequencies associated with the dominant and sub-dominant vortices. Heating up the cylinder wall leads to a delayed flow separation and narrower wake flow, giving lesser space for the sequence of counter-rotating vortices. This spatial limitation does not only reduce the amplitude of the oscillating wake flow it also shifts the dominant frequency to higher frequencies, furthermore it damps higher harmonics. Eventually the locally heated wake flow smears out. Eventually, the CFD simulation results of the systematically varied thermal flow parameter study have been used to describe a relation for the main characteristic order parameters.

Keywords: Heat transfer, thermo-viscous fluids, shear thinning, vortex shedding.

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Authors: Pavana Manvikar, G K Purohit

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The functional performance of machined components, often, depends on surface topography, hardness, nature of stress and strain induced on the surface, etc. Invariably, surfaces of metallic components obtained by turning, milling, etc., consist of irregularities such as machining marks are responsible for the above. Surface finishing/coating processes used to produce improved surface quality/textures are classified as chip-removal and chip-less processes. Burnishing is chip-less cold working process carried out to improve surface finish, hardness and resistance to fatigue and corrosion; not obtainable by other surface coating and surface treatment processes. It is a very simple, but effective method which improves surface characteristics and is reported to introduce compressive stresses.

Of late, considerable attention is paid to post-machining, finishing operations, such as burnishing. During burnishing the micro-irregularities start to deform plastically, initially the crests are gradually flattened and zones of reduced deformation are formed. When all the crests are deformed, the valleys between the micro-irregularities start moving in the direction of the newly formed surface. The grain structure is then condensed, producing a smoother and harder surface with superior load-carrying and wear-resistant capabilities.

Burnishing can be performed on a lathe with a highly polished ball or roller type tool which is traversed under force over a rotating/stationary work piece. Often, several passes are used to obtain the work piece surface with the desired finish and hardness.

This paper presents the findings of an experimental investigation on the effect of ball burnishing parameters such as, burnishing speed, feed, force and number of passes; on surface roughness (Ra) and micro-hardness (Hv) of a 60/40 copper/zinc alloy, using a 2-level fractional factorial design of experiments (DoE). Mathematical models were developed to predict surface roughness and hardness generated by burnishing in terms of the above process parameters. A ball-type tool, designed and constructed from a high chrome steel material (HR_C=63 and Ra=0.012 µm), was used for burnishing of fine-turned cylindrical bars (0.68-0.78µm and 145Hv). They are given by,

 

Ra= 0.305-0.005X₁ - 0.0175X₂ + 0.0525X₄ + 0.0125X₁X₄ -0.02X₂X₄ - 0.0375X₃X₄

 

Hv=160.625 -2.37 5X₁ + 5.125X₂ + 1.875X₃ + 4.375X₄ - 1.625X₁X₄ + 4.375X₂X₄ - 2.375X₃X₄

 

High surface microhardness (175H_V) was obtained at 400rpm, 2passes, 0.05mm/rev and 15kgf., and high surface finish (0.20µm) was achieved at 30kgf, 0.1mm/rev, 112rpm and single pass. In other words, surface finish improved by 350% and microhardness improved by 21% compared to as machined conditions.

Keywords: Ball burnishing, surface roughness, micro-hardness.

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Authors: Douglas N. Simões, Michele Pittol, Vanda F. Ribeiro, Daiane Tomacheski, Ruth M. C. Santana

Abstract:

The increasing demand of thermoplastic elastomers is related to the wide range of applications, such as automotive, footwear, wire and cable industries, adhesives and medical devices, cell phones, sporting goods, toys and others. These materials are susceptible to microbial attack. Moisture and organic matter present in some areas (such as shower area and sink), provide favorable conditions for microbial proliferation, which contributes to the spread of diseases and reduces the product life cycle. Compounds based on SEBS copolymers, poly(styrene-b-(ethylene-co-butylene)-b-styrene, are a class of thermoplastic elastomers (TPE), fully recyclable and largely used in domestic appliances like bath mats and tooth brushes (soft touch). Zinc oxide and zinc ions loaded in personal and home care products have become common in the last years due to its biocidal effect. In that sense, the aim of this study was to evaluate the effect of zinc as antimicrobial agent in compounds based on SEBS/polypropylene/oil/ calcite for use as refrigerator seals (gaskets), bath mats and sink squeegee. Two zinc oxides from different suppliers (ZnO-Pe and ZnO-WR) and one masterbatch of zinc ions (M-Zn-ion) were used in proportions of 0%, 1%, 3% and 5%. The compounds were prepared using a co-rotating double screw extruder (L/D ratio of 40/1 and 16 mm screw diameter). The extrusion parameters were kept constant for all materials. Tests specimens were prepared using the injection molding machine. A compound with no antimicrobial additive (standard) was also tested. Compounds were characterized by physical (density), mechanical (hardness and tensile properties) and rheological properties (melt flow rate - MFR). The Japan Industrial Standard (JIS) Z 2801:2010 was applied to evaluate antibacterial properties against Staphylococcus aureus (S. aureus) and Escherichia coli (E. coli). The Brazilian Association of Technical Standards (ABNT) NBR 15275:2014 were used to evaluate antifungal properties against Aspergillus niger (A. niger), Aureobasidium pullulans (A. pullulans), Candida albicans (C. albicans), and Penicillium chrysogenum (P. chrysogenum). The microbiological assay showed a reduction over 42% in E. coli and over 49% in S. aureus population. The tests with fungi showed inconclusive results because the sample without zinc also demonstrated an inhibition of fungal development when tested against A. pullulans, C. albicans and P. chrysogenum. In addition, the zinc loaded samples showed worse results than the standard sample when tested against A. niger. The zinc addition did not show significant variation in mechanical properties. However, the density values increased with the rise in ZnO additives concentration, and had a little decrease in M-Zn-ion samples. Also, there were differences in the MFR results in all compounds compared to the standard.

Keywords: Antimicrobial, home device, SEBS, zinc.

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