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DOI: 10.1186/s10033-019-0370-6
Effects of Four Types of Pre-swirls on the Leakage, Flow Field, and Fluid-Induced Force of the Rotary Straight-through Labyrinth Gas Seal
Qingfeng Wang and Lidong He
Abstract: The labyrinth seal in turbomachinery is a key element that restricts leakage flow among rotor-stator clearances from high-pressure regions to low-pressure regions. The fluid-induced forces on the rotor from seals during machine operation must be accurately quantified to predict their dynamic behavior effectively. To understand the fluid-induced force characteristics of the labyrinth seal more fully, the effects of four types of pre-swirls on the leakage, flow field, and fluid-induced force of a rotary straight-through labyrinth gas seal (RSTLGS) were numerically investigated using the proposed steady computational fluid dynamics (CFD) method based on the three-dimensional models of the RSTLGS. The leakage, flow field, and fluid-induced force of the RSTLGS for six axial pre-swirl velocities, four radial pre-swirl angles, four circumferential positive pre-swirl angles, and four circumferential negative pre-swirl angles were computed under the same geometrical parameters and operational conditions. Mesh analysis ensures the accuracy of the present steady CFD method. The numerical results show that the four types of pre-swirls influence the leakage, flow field, and fluid-induced force of the RSTLGS. The axial pre-swirl velocity remarkably inhibits the fluid-induced force, and the circumferential positive pre-swirl angle and circumferential negative pre-swirl angle remarkably promote the fluid-induced force. The effects of the radial pre-swirl angle on the fluid-induced force are complicated, and the pressure forces and viscous forces show the maximum or minimum values at a specific radial pre-swirl angle. The pre-swirl has a negligible impact on the leakage. The four types of pre-swirls affect the leakage, flow field, and fluid-induced force of the RSTLGS to varying degrees. The pre-swirl is the influence factor affecting the leakage, flow field, and fluid-induced force of the RSTLGS. The conclusions will help to understand the fluid-induced force of labyrinth seals more fully, by providing helpful suggestions for engineering practices and a theoretical basis to analyze the fluid–structure interaction of the seal-rotor system in future research.
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https://cjme.springeropen.com/articles/10.1186/s10033-019-0370-6
DOI: 10.1186/s10033-019-0366-2
Penetration Estimation of GMA Backing Welding Based on Weld Pool Geometry Parameters
Junfen Huang,Long Xue,Jiqiang Huang,Yong Zou and Ke Ma
Abstract: Penetration estimation is a prerequisite of the automation of backing welding based on vision sensing technology. However, the arc interference in welding process leads to the difficulties of extracting the weld pool characteristic information, which brings great challenges to the penetration estimation. At present, most researches focus on the extraction of weld pool geometry parameters, and the visual sensing systems are complex in structure and complicated in the image processing algorithms. The research of penetration estimation based on weld pool geometry parameters is still in the exploratory stage. The purpose of this paper is to research the relationship between the weld pool geometry parameters and the penetration during backing welding and to estimate penetration using the weld pool geometry parameters. A passive vision sensing test system for gas metal arc (GMA) backing welding was established. An image processing algorithm was developed to extract the weld pool geometry parameters, namely, the area, maximum width and length, half-length, length-width ratio and advancing contact angle (simplified as AWP, MWWP, MLWP, HLWP, LWR and ACA, respectively). The corresponding relationships between the weld pool geometry parameters and the penetration state were explored by analysing their changes with the welding current and speed. The distribution of the weld pool geometry parameters corresponding to penetration was determined. When the AWP of the weld pool is within a certain range and the values of LWR and ACA are close to their maximum and minimum respectively, the penetration is in good condition. A mathematical model with the weld pool geometry parameters as independent variables and the back-bead width (the indicator of the penetration state) as a dependent variable was established based on multivariable linear regression analysis, and relevant statistical tests were carried out. Multivariable linear regression equations for the weld pool geometry parameters and the back-bead width were deduced according to the variations in the current and speed, and the equations can be used to estimate the penetration of backing welding. The study provides a solution to penetration estimation of GMA backing welding based on automatic vision sensing.
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https://cjme.springeropen.com/articles/10.1186/s10033-019-0366-2
DOI: 10.1186/s10033-019-0369-z
On Generating Expected Kinetostatic Nonlinear Stiffness Characteristics by the Kinematic Limb-Singularity of a Crank-Slider Linkage with Springs
Baokun Li and Guangbo Hao
Abstract: Being different from avoidance of singularity of closed-loop linkages, this paper employs the kinematic singularity to construct compliant mechanisms with expected nonlinear stiffness characteristics to enrich the methods of compliant mechanisms synthesis. The theory for generating kinetostatic nonlinear stiffness characteristic by the kinematic limb-singularity of a crank-slider linkage is developed. Based on the principle of virtual work, the kinetostatic model of the crank-linkage with springs is established. The influences of spring stiffness on the toque-position angle relation are analyzed. It indicates that corresponding spring stiffness may generate one of four types of nonlinear stiffness characteristics including the bi-stable, local negative-stiffness, zero-stiffness or positive-stiffness when the mechanism works around the kinematic limb-singularity position. Thus the compliant mechanism with an expected stiffness characteristic can be constructed by employing the pseudo rigid-body model of the mechanism whose joints or links are replaced by corresponding flexures. Finally, a tri-symmetrical constant-torque compliant mechanism is fabricated, where the curve of torque-position angle is obtained by an experimental testing. The measurement indicates that the compliant mechanism can generate a nearly constant-torque zone.
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https://cjme.springeropen.com/articles/10.1186/s10033-019-0369-z
DOI: 10.1186/s10033-019-0368-0
Design and Manufacturing Strategies for Fused Deposition Modelling in Additive Manufacturing: A Review
Abstract: Although several research works in the literature have focused on studying the capabilities of additive manufacturing (AM) systems, few works have addressed the development of Design for Additive Manufacturing (DfAM) knowledge, tools, rules, and methodologies, which has limited the penetration and impact of AM in industry. In this paper a comprehensive review of design and manufacturing strategies for Fused Deposition Modelling (FDM) is presented. Consequently, several DfAM strategies are proposed and analysed based on existing research works and the operation principles, materials, capabilities and limitations of the FDM process. These strategies have been divided into four main groups: geometry, quality, materials and sustainability. The implementation and practicality of the proposed DfAM is illustrated by three case studies. The new proposed DfAM strategies are intended to assist designers and manufacturers when making decisions to satisfy functional needs, while ensuring manufacturability in FDM systems. Moreover, many of these strategies can be applied or extended to other AM processes besides FDM.
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https://cjme.springeropen.com/articles/10.1186/s10033-019-0368-0
DOI: 10.1186/s10033-019-0364-4
Micro Model of Carbon Fiber/Cyanate Ester Composites and Analysis of Machining Damage Mechanism
Haitao Liu,Jie Lin,Yazhou Sun and Jinyang Zhang
Abstract: Machining damage occurs on the surface of carbon fiber reinforced polymer (CFRP) composites during processing. In the current simulation model of CFRP, the initial defects on the carbon fiber and the periodic random distribution of the reinforcement phase in the matrix are not considered in detail, which makes the characteristics of the cutting model significantly different from the actual processing conditions. In this paper, a novel three-phase model of carbon fiber/cyanate ester composites is proposed to simulate the machining damage of the composites. The periodic random distribution of the carbon fiber reinforced phase in the matrix was realized using a double perturbation algorithm. To achieve the stochastic distribution of the strength of a single carbon fiber, a novel method that combines the Weibull intensity distribution theory with the Monte Carlo method is presented. The mechanical properties of the cyanate matrix were characterized by fitting the stress-strain curves, and the cohesive zone model was employed to simulate the interface. Based on the model, the machining damage mechanism of the composites was revealed using finite element simulations and by conducting a theoretical analysis. Furthermore, the milling surfaces of the composites were observed using a scanning electron microscope, to verify the accuracy of the simulation results. In this study, the simulations and theoretical analysis of the carbon fiber/cyanate ester composite processing were carried out based on a novel three-phase model, which revealed the material failure and machining damage mechanism more accurately.
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https://cjme.springeropen.com/articles/10.1186/s10033-019-0364-4
DOI: 10.1186/s10033-019-0365-3
Methodology to Evaluate Fatigue Damage of High-Speed Train Welded Bogie Frames Based on On-Track Dynamic Stress Test Data
Guangxue Yang,Meng Wang,Qiang Li and Ran Ding
Abstract: The current method of estimating the fatigue life of railway structures is to calculating the equivalent stress amplitude based on the measured stress data. However, the random of the measured data is not considered. In this paper, a new method was established to compute the equivalent stress amplitude to evaluate the fatigue damage based on the measurable randomness, since the equivalent stress is the key parameter for assessment of structure fatigue life and load derivation. The equivalent stress amplitude of a high-speed train welded bogie frame was found to obey normal distribution under uniform operation route that verified by on-track dynamic stress data, and the proposed model is, in effect, an improved version of the mathematical model used to calculate the equivalent stress amplitude. The data of a long-term, on-track dynamic stress test program was analyzed to find that the normal distribution parameters of equivalent stress amplitude values differ across different operation route. Thus, the fatigue damage of the high-speed train welded bogie frame can be evaluated by the proposed method if the running schedule of the train is known a priori. The results also showed that the equivalent stress amplitude of the region connected to the power system is more random than in other regions of the bogie frame.
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https://cjme.springeropen.com/articles/10.1186/s10033-019-0365-3
DOI: 10.1186/s10033-019-0363-5
Effect of Heat Sink and Cooling Mediums on Ferrite Austenite Ratio and Distortion in Laser Welding of Duplex Stainless Steel 2205
P. Dinesh Babu,P. Gouthaman and P. Marimuthu
Abstract: In order to control the ferrite and austenite percentage in duplex stainless steel welding, many researchers try to change the laser welding parameters and cooling medium, but ignore to study the influence of heat sink effect on weld strength. In this work, the effect of aluminium heat sink and varying cooling medium on the laser welding of duplex stainless steel (DSS) 2205 is studied. The 2 mm thick DSS sheets welded with pulsed Nd: YAG laser welding machine by varying the cooling medium (air and oil) and an aluminium plate used as a heat sink. The welded specimens tested for tensile strength, micro-hardness, distortion, microstructure and radiography analysis. The faster cooling rate in the oil quenching process enhances the ferrite percentage compared with air-cooled samples. But the faster cooling rate in oil quenching leads to more distortion and using aluminium as a heat sink influenced positively the distortion to a small extent. The lower cooling rate in air quenching leads to a higher tensile strength of the welded specimen. The objective of this work is to analyse experimentally the effect of cooling medium and heat sink in the mechanical and metallurgical properties of laser welded duplex stainless steel.
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https://cjme.springeropen.com/articles/10.1186/s10033-019-0363-5
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