Abstract: A controlled cutting fluid impinging supply system (CUT-LIST) was developed to deliver an accurate amount of cutting fluid into the machining zone via well-positioned coherent nozzles based on a calculation of the heat generated. The performance of the CUT-LIST was evaluated against a conventional flood cutting fluid supply system during step shoulder milling of Ti-6Al-4V using vegetable oil-based cutting fluid. In this paper, the micro-hardness of the machined surface was used as the main criterion to compare the two systems. CUT-LIST provided significant reductions in cutting fluid consumption (up to 42%). Both systems caused increased micro-hardness value at 100 µm from the machined surface, whereas a slight reduction in micro-hardness of 4.5% was measured when using CUL-LIST. It was noted that the first 50 µm is the soft sub-surface promoted by thermal softening, whereas down to 100 µm is the hard sub-surface caused by the cyclic internal work hardening and then gradually decreased until it reached the base material nominal hardness. It can be concluded that the CUT-LIST has always given lower micro-hardness values near the machined surfaces in all conditions investigated.
Abstract: The paper aims to extend the knowledge about jet behavior and jet interaction between five plane unventilated jets with large aspect ratio (AR). The distance between the single plane jets is two times the channel height. The experimental investigation applies 2D Particle Image Velocimetry (PIV) and static pressure measurements. Our study focuses on the influence of two different outlet nozzle geometries (triangular shape with 2 x 7.5° and blunt geometry) with respect to variation of Reynolds number from 5500 - 12000. It is shown that the outlet geometry has a major influence on the jet formation in terms of uniformity of velocity profiles downstream of the sudden expansion. Furthermore, we describe characteristic regions like converging region, merging region and combined region. The triangular outlet geometry generates most uniform velocity distributions in comparison to a blunt outlet nozzle geometry. The blunt outlet geometry shows an unstable behavior where the jets tend to attach to one side of the walls (ceiling) generating a large recirculation region on the opposite side. Static pressure measurements confirm the observation and indicate that the recirculation region is connected to larger pressure drop.
Abstract: The performance of jet grout columns was affected by many controlled and uncontrolled parameters. The leading parameters for the controlled ones can be listed as injection pressure, rod pulling speed, rod rotation speed, number of nozzles, nozzle diameter and Water/Cement ratio. And the uncontrolled parameters are soil type, soil structure, soil layering condition, underground water level, the changes in strength parameters and the rheologic properties of cement in time. In this study, the performance of jet grout columns and the effects of pulling speed and rotation speed were investigated experimentally. For this purpose, a laboratory type jet grouting system was designed for the experiments. Through this system, jet grout columns were produced in three different conditions. The results of the study showed that the grout pressure and the lifting speed significantly affect the performance of the jet grouting columns.
Abstract: Liquid sprays of water are frequently used in air pollution control for gas cooling purposes and for gas cleaning. Twin-fluid nozzles with internal mixing are often used for these purposes because of the small size of the drops produced. In these nozzles the liquid is dispersed by compressed air or another pressurized gas. In high efficiency scrubbers for particle separation, several nozzles are operated in parallel because of the size of the cross section. In such scrubbers, the scrubbing water has to be re-circulated. Precipitation of some solid material can occur in the liquid circuit, caused by chemical reactions. When such precipitations are detached from the place of formation, they can partly or totally block the liquid flow to a nozzle. Due to the resulting unbalanced supply of the nozzles with water and gas, the efficiency of separation decreases. Thus, the nozzles have to be cleaned if a certain fraction of blockages is reached. The aim of this study was to provide a tool for continuously monitoring the status of the nozzles of a scrubber based on the available operation data (water flow, air flow, water pressure and air pressure). The difference between the air pressure and the water pressure is not well suited for this purpose, because the difference is quite small and therefore very exact calibration of the pressure measurement would be required. Therefore, an equation for the reference air flow of a nozzle at the actual water flow and operation pressure was derived. This flow can be compared with the actual air flow for assessment of the status of the nozzles.
Abstract: Supersonic nozzles are commonly used to purify natural gas in gas processing technology. As an innovated technology, it is employed to overcome the deficit of the traditional method, related to gas dynamics, thermodynamics and fluid dynamics theory. An indoor test rig is built to study the dehumidification process of moisture fluid. Humid air was chosen for the study. The working fluid was circulating in an open loop, which had provision for filtering, metering, and humidifying. A stainless steel supersonic separator is constructed together with the C-D nozzle system. The result shows that dehumidification enhances as NPR increases. This is due to the high intensity in the turbulence caused by the shock formation in the divergent section. Such disturbance strengthens the centrifugal force, pushing more particles toward the near-wall region. In return return, the pressure recovery factor, defined as the ratio of the outlet static pressure of the fluid to its inlet value, decreases with NPR.
Abstract: Air jet weaving is the most productive, but also the most energy consuming weaving method. Increasing energy costs and environmental impact are constantly a challenge for the manufacturers of weaving machines. Current technological developments concern with low energy costs, low environmental impact, high productivity, and constant product quality. The high degree of energy consumption of the method can be ascribed to the high need of compressed air. An energy efficiency method is applied to the air jet weaving technology. Such method identifies and classifies the main relevant energy consumers and processes from the exergy point of view and it leads to the identification of energy efficiency potentials during the weft insertion process. Starting from the design phase, energy efficiency is considered as the central requirement to be satisfied. The initial phase of the method consists of an analysis of the state of the art of the main weft insertion components in order to point out a prioritization of the high demanding energy components and processes. The identified major components are investigated to reduce the high demand of energy of the weft insertion process. During the interaction of the flow field coming from the relay nozzles within the profiled reed, only a minor part of the stream is really accelerating the weft yarn, hence resulting in large energy inefficiency. Different tools such as FEM analysis, CFD simulation models and experimental analysis are used in order to design a more energy efficient design of the involved components in the filling insertion. A different concept for the metal strip of the profiled reed is developed. The developed metal strip allows a reduction of the machine energy consumption. Based on a parametric and aerodynamic study, the designed reed transmits higher values of the flow power to the filling yarn. The innovative reed fulfills both the requirement of raising energy efficiency and the compliance with the weaving constraints.
Abstract: A jet pump is a type of pump that accelerates the flow of a secondary fluid (driven fluid) by introducing a motive fluid with high velocity into a converging-diverging nozzle. Jet pumps are also known as adductors or ejectors depending on the motivator phase. The ejector's motivator is of a gaseous nature, usually steam or air, while the educator's motivator is a liquid, usually water. Jet pumps are devices that use air bubbles and are widely used in wastewater treatment processes. In this work, we will discuss about the characteristics of the jet pump and the computational simulation of this device. To find the optimal angle and depth for the air pipe, so as to achieve the maximal air volumetric flow rate, an experimental apparatus was constructed to ascertain the best geometrical configuration for this new type of jet pump. By using 3D printing technology, a series of jet pumps was printed and tested whilst aspiring to maximize air flow rate dependent on angle and depth of the air pipe insertion. The experimental results show a major difference of up to 300% in performance between the different pumps (ratio of air flow rate to supplied power) where the optimal geometric model has an insertion angle of 600 and air pipe insertion depth ending at the center of the mixing chamber. The differences between the pumps were further explained by using CFD for better understanding the reasons that affect the airflow rate. The validity of the computational simulation and the corresponding assumptions have been proved experimentally. The present research showed high degree of congruence with the results of the laboratory tests. This study demonstrates the potential of using of the jet pump in many practical applications.
Abstract: The amount of the electrical power required by refrigeration systems is relevant worldwide. It is evaluated in the order of 15% of the total electricity production taking refrigeration and air-conditioning into consideration. For this reason, in the last years several energy saving techniques have been proposed to reduce the power demand of such plants. The paper deals with the development of an innovative internal recovery system for cryogenic cooling plants. Such a system consists in a Compressor-Expander Group (CEG) designed on the basis of the automotive turbocharging technology. In particular, the paper is focused on the design of the expander, the critical component of the CEG system. Due to the low volumetric flow entering the expander and the high expansion ratio, a commercial turbocharger expander wheel was strongly modified. It was equipped with a transonic nozzle, designed to have a radially inflow full admission. To verify the performance of such a machine and suggest improvements, two different set of nozzles have been designed and modelled by means of the commercial Ansys-CFX software. steady-state 3D CFD simulations of the second-generation prototype are presented and compared with the initial ones.
Abstract: There is a gap at combustor-turbine interface where leakage flow comes out to prevent hot gas ingestion into the gas turbine nozzle platform. The leakage flow protects the nozzle endwall surface from the hot gas coming from combustor exit. For controlling flow’s stream, the gap’s geometry is transformed by changing fillet radius size. During the operation, step configuration is occurred that was unintended between combustor-turbine platform interface caused by thermal expansion or mismatched assembly. In this study, CFD simulations were performed to investigate the effect of the fillet and step on heat transfer and film cooling effectiveness on the nozzle platform. The Reynolds-averaged Navier-stokes equation was solved with turbulence model, SST k-omega. With the fillet configuration, predicted film cooling effectiveness results indicated that fillet radius size influences to enhance film cooling effectiveness. Predicted film cooling effectiveness results at forward facing step configuration indicated that step height influences to enhance film cooling effectiveness. We suggested that designer change a combustor-turbine interface configuration which was varied by fillet radius size near endwall gap when there was a step at combustor-turbine interface. Gap shape was modified by increasing fillet radius size near nozzle endwall. Also, fillet radius and step height were interacted with the film cooling effectiveness and heat transfer on endwall surface.
Abstract: In this current era of competitive machinery productions, the industries are designed to place more emphasis on the product quality and reduction of cost whilst abiding by the pollution-preventing policy. In attempting to delve into the concerns, the industries are aware that the effectiveness of existing lubrication systems must be improved to achieve power-efficient and pollution-preventing machining processes. As such, this research is targeted to study on a plausible solution to the issue in grinding titanium alloy (Ti-6Al-4V) by using nanolubrication, as an alternative to flood grinding. The aim of this research is to evaluate the optimum condition of grinding force and surface roughness using MQL lubricating system to deliver nano-oil at different level of weight concentration of Silicon Dioxide (SiO2) mixed normal mineral oil. Taguchi Design of Experiment (DoE) method is carried out using a standard Taguchi orthogonal array of L16(43) to find the optimized combination of weight concentration mixture of SiO2, nozzle orientation and pressure of MQL. Surface roughness and grinding force are also analyzed using signal-to-noise(S/N) ratio to determine the best level of each factor that are tested. Consequently, the best combination of parameters is tested for a period of time and the results are compared with conventional grinding method of dry and flood condition. The results show a positive performance of MQL nanolubrication.
Abstract: Compressor fans in modern aircraft engines are of considerate importance, as they provide majority of thrust required by the aircraft. Their challenging environment is frequently subjected to non-uniform inflow conditions. These conditions could be either due to the flight operating requirements such as take-off and landing, wake interference from aircraft fuselage or cross-flow wind conditions. So, in highly maneuverable flights regimes of fighter aircrafts affects the overall performance of an engine. Since the flow in compressor of an aircraft application is highly sensitive because of adverse pressure gradient due to different flow orientations of the aircraft. Therefore, it is prone to unstable operations. This paper presents the study that focuses on axial compressor response to inlet flow orientations for the range of angles as 0 to 15 degrees. For this purpose, NASA Rotor-37 was taken and CFD mesh was developed. The compressor characteristics map was generated for the design conditions of pressure ratio of 2.106 with the rotor operating at rotational velocity of 17188.7 rpm using CFD simulating environment of ANSYS-CFX®. The grid study was done to see the effects of mesh upon computational solution. Then, the mesh giving the best results, (when validated with the available experimental NASA’s results); was used for further distortion analysis. The flow in the inlet nozzle was given angle orientations ranging from 0 to 15 degrees. The CFD results are analyzed and discussed with respect to stall margin and flow separations due to induced distortions.
Abstract: The source of the jet noise is generated by rocket exhaust plume during rocket engine testing. A domain decomposition approach is applied to the jet noise prediction in this paper. The aerodynamic noise coupling is based on the splitting into acoustic sources generation and sound propagation in separate physical domains. Large Eddy Simulation (LES) is used to simulate the supersonic jet flow. Based on the simulation results of the flow-fields, the jet noise distribution of the sound pressure level is obtained by applying the Ffowcs Williams-Hawkings (FW-H) acoustics equation and Fourier transform. The calculation results show that the complex structures of expansion waves, compression waves and the turbulent boundary layer could occur due to the strong interaction between the gas jet and the ambient air. In addition, the jet core region, the shock cell and the sound pressure level of the gas jet increase with the nozzle size increasing. Importantly, the numerical simulation results of the far-field sound are in good agreement with the experimental measurements in directivity.
Abstract: This paper outlines the development of an
experimental technique in quantifying supersonic jet flows, in an
attempt to avoid seeding particle problems frequently associated with
particle-image velocimetry (PIV) techniques at high Mach numbers.
Based on optical flow algorithms, the idea behind the technique
involves using high speed cameras to capture Schlieren images of the
supersonic jet shear layers, before they are subjected to an adapted
optical flow algorithm based on the Horn-Schnuck method to
determine the associated flow fields. The proposed method is capable
of offering full-field unsteady flow information with potentially
higher accuracy and resolution than existing point-measurements or
PIV techniques. Preliminary study via numerical simulations of a
circular de Laval jet nozzle successfully reveals flow and shock
structures typically associated with supersonic jet flows, which serve
as useful data for subsequent validation of the optical flow based
experimental results. For experimental technique, a Z-type Schlieren
setup is proposed with supersonic jet operated in cold mode,
stagnation pressure of 4 bar and exit Mach of 1.5. High-speed singleframe
or double-frame cameras are used to capture successive
Schlieren images. As implementation of optical flow technique to
supersonic flows remains rare, the current focus revolves around
methodology validation through synthetic images. The results of
validation test offers valuable insight into how the optical flow
algorithm can be further improved to improve robustness and
accuracy. Despite these challenges however, this supersonic flow
measurement technique may potentially offer a simpler way to
identify and quantify the fine spatial structures within the shock shear
layer.
Abstract: Considering the challenges of short product life cycles
and growing variant diversity, cost minimization and manufacturing
flexibility increasingly gain importance to maintain a competitive
edge in today’s global and dynamic markets. In this context, an
aerodynamic part feeding system for high-speed industrial assembly
applications has been developed at the Institute of Production
Systems and Logistics (IFA), Leibniz Universitaet Hannover. The
aerodynamic part feeding system outperforms conventional systems
with respect to its process safety, reliability, and operating speed. In
this paper, a multi-objective optimisation of the aerodynamic feeding
system regarding the orientation rate, the feeding velocity, and the
required nozzle pressure is presented.
Abstract: In this study, failure analysis of pipe system at a micro
hydroelectric power plant is investigated. Failure occurred at the pipe
system in the powerhouse during shut down operation of the water
flow by a valve. This locking had caused a sudden shock wave, also
called “Water-hammer effect”, resulting in noise and inside pressure
increase. After visual investigation of the effect of the shock wave on
the system, a circumference crack was observed at the pipe flange
weld region. To establish the reason for crack formation, calculations
of pressure and stress values at pipe, flange and welding seams were
carried out and concluded that safety factor was high (2.2), indicating
that no faulty design existed. By further analysis, pipe system and
hydroelectric power plant was examined. After observations it is
determined that the plant did not include a ventilation nozzle (air
trap), that prevents the system of sudden pressure increase inside the
pipes which is caused by water-hammer effect. Analyses were carried
out to identify the influence of water-hammer effect on inside
pressure increase and it was concluded that, according Jowkowsky’s
equation, shut down time is effective on inside pressure increase. The
valve closing time was uncertain but by a shut down time of even one
minute, inside pressure would increase by 7.6 bar (working pressure
was 34.6 bar). Detailed investigations were also carried out on the
assembly of the pipe-flange system by considering technical
drawings. It was concluded that the pipe-flange system was not
installed according to the instructions. Two of five weld seams were
not applied and one weld was carried out faulty. This incorrect and
inadequate weld seams resulted in; insufficient connection of the pipe
to the flange constituting a strong notch effect at weld seam regions,
increase in stress values and the decrease of strength and safety
factor.
Abstract: Traditional mechanical control systems in thrust
vectoring are efficient in rocket thrust guidance but their costs
and their weights are excessive. The fluidic injection in the nozzle
divergent constitutes an alternative procedure to achieve the goal. In
this paper, we present a 3D analytical model for fluidic injection
in a supersonic nozzle integrating an orifice. The fluidic vectoring
uses a sonic secondary injection in the divergent. As a result, the
flow and interaction between the main and secondary jet has built in
order to express the pressure fields from which the forces and thrust
vectoring are deduced. Under various separation criteria, the present
analytical model results are compared with the existing numerical
and experimental data from the literature.
Abstract: The effects of flame-holder position, the ratio of flame
holder diameter to combustion chamber diameter and injection angle
on fuel propulsive droplets sizing and effective mass fraction have
been studied by a cold flow. We named the mass of fuel vapor inside
the flammability limit as the effective mass fraction. An empty
cylinder as well as a flame-holder which are a simulator for duct
combustion has been considered. The airflow comes into the cylinder
from one side and injection operation will be done by four nozzles
which are located on the entrance of cylinder. To fulfill the
calculations a modified version of KIVA-3V code which is a
transient, three-dimensional, multiphase, multi component code for
the analysis of chemically reacting flows with sprays, is used.
Abstract: Numerical studies have been carried out using a
validated two-dimensional standard k-omega turbulence model for
the design optimization of a thrust vector control system using shock
induced self-impinging supersonic secondary double jet. Parametric
analytical studies have been carried out at different secondary
injection locations to identifying the highest unsymmetrical
distribution of the main gas flow due to shock waves, which produces
a desirable side force more lucratively for vectoring. The results from
the parametric studies of the case on hand reveal that the shock
induced self-impinging supersonic secondary double jet is more
efficient in certain locations at the divergent region of a CD nozzle
than a case with supersonic single jet with same mass flow rate. We
observed that the best axial location of the self-impinging supersonic
secondary double jet nozzle with a given jet interaction angle, built-in
to a CD nozzle having area ratio 1.797, is 0.991 times the primary
nozzle throat diameter from the throat location. We also observed
that the flexible steering is possible after invoking ON/OFF facility to
the secondary nozzles for meeting the onboard mission requirements.
Through our case studies we concluded that the supersonic self-impinging
secondary double jet at predesigned jet interaction angle
and location can provide more flexible steering options facilitating
with 8.81% higher thrust vectoring efficiency than the conventional
supersonic single secondary jet without compromising the payload
capability of any supersonic aerospace vehicle.
Abstract: This paper reports a novel actuating design that uses
the shear deformation of a piezoelectric actuator to deflect a
bulge-diaphragm for driving an array microdroplet ejector. In essence,
we employed a circular-shaped actuator poled radial direction with
remnant polarization normal to the actuating electric field for inducing
the piezoelectric shear effect. The array microdroplet ejector consists
of a shear type piezoelectric actuator, a vibration plate, two chamber
plates, two channel plates and a nozzle plate. The vibration, chamber
and nozzle plate components are fabricated using nickel
electroforming technology, whereas the channel plate is fabricated by
etching of stainless steel. The diaphragm displacement was measured
by the laser two-dimensional scanning vibrometer. The ejected
droplets of the microejector were also observed via an optic
visualization system.
Abstract: Nanofibers are effective materials which have
frequently been investigated to produce high quality air filters. As an
environmental approach our aim is to achieve nanofibers by melting.
In spun-bond systems extruder, spin-pump, nozzle package and
attenuator are used. Molten polymer which flows from extruder is
made steady by spin-pump. Regular melt passes through nozzle holes
and forms fibers under high pressure. The fibers pulled from nozzle
are shrunk to micron size by an attenuator; after solidification, they
are collected on a conveyor. In this research different designs of
attenuator system have been studied; and also CFD analysis has been
done on these different designs. Afterwards, one of these designs
tested and finally some optimizations have been done to reduce
pressure loss and increase air velocity.