Flow Uniformity Characterization and Its Application in Extruder Flow Channel Design Optimization

2009 ◽  
Author(s):  
Minwu Yao ◽  
Ching-Chih Lee
Keyword(s):  
Design Optimization ◽  
Cross Section ◽  
Search Space ◽  
Flow Channel ◽  
Channel Cross Section ◽  
Optimization Approach ◽  
Flow Uniformity ◽  
Element Analysis ◽  
Automated Optimization ◽  
Optimization Loop

We are interested in developing a general design optimization loop for extruder flow channel inserts based on 3-D finite element analysis (FEA). A key step of the computational procedure is the automated flow uniformity assessment which requires a quantitative characterization of the flow uniformity at the exit opening. To this end, a non-dimensional flow uniformity parameter is proposed, which is independent of flow rate & geometric dimensions and applicable to any shape of the flow channel cross-section. For a rectangular exit opening, two additional flow uniformity parameters are used to characterize the flow distribution in the two principal directions of the exit cross-section. The proposed flow uniformity parameter was successfully used as the objective function in an automated optimization loop for geometric design of flow channel inserts. The automated optimization loop allowed us to explore the design space in a broad range. Simulation results show that flow balance is consistently improved with the expansion of the design search space. It was also found that the automated optimization loop provides a better optimal solution than those obtained from the manual optimization approach under the same pressure-drop constraint.

A New Approach to Design of a Lightweight Anthropomorphic Arm for Service Applications

2015 ◽  
Vol 7 (3) ◽  
Author(s):  
Lelai Zhou ◽  
Shaoping Bai
Keyword(s):  
Design Optimization ◽  
Integrated Design ◽  
Robot Kinematics ◽  
Strength Analysis ◽  
Optimization Approach ◽  
Element Analysis ◽  
New Approach ◽  
Design Variables ◽  
Kinematic Performance ◽  
Service Application

This paper describes a new approach to the design of a lightweight robotic arm for service applications. A major design objective is to achieve a lightweight robot with desired kinematic performance and compliance. This is accomplished by an integrated design optimization approach, where robot kinematics, dynamics, drive-train design and strength analysis by means of finite element analysis (FEA) are generally considered. In this approach, kinematic dimensions, structural dimensions, and the motors and the gearboxes are parameterized as design variables. Constraints are formulated on the basis of kinematic performance, dynamic requirements and structural strength limitations, whereas the main objective is to minimize the weight. The design optimization of a five degree-of-freedom (dof) lightweight arm is demonstrated and the robot development for service application is also presented.

Taguchi Methodology to Optimize the Design of a MR-Brake With Permanent Magnet

2012 ◽  
Author(s):  
Ozan Erol ◽  
Hakan Gurocak
Keyword(s):  
Permanent Magnet ◽  
Volume Ratio ◽  
Search Space ◽  
Friction Torque ◽  
Optimization Techniques ◽  
Design Parameters ◽  
Physical Factors ◽  
Optimization Approach ◽  
Taguchi Optimization ◽  
Element Analysis

Magnetorheological (MR) brakes provide variable friction torque by electronically changing the viscosity of a magnetic fluid inside the actuator. The MR-brakes have many desirable characteristics, such as high torque-to-volume ratio, inherent stability and ease of control. However, the design process of such an actuator is complex and time consuming due to many parameters involved in the design, including geometric and physical factors and their interactions. The first contribution of this research is a new optimization approach where we combined the Taguchi optimization method with parameterized magnetic finite element analysis. Unlike other optimization techniques, this method can identify the dominant parameters of the design and investigate their interactions with the design output while reducing the search space and the design time. The second contribution is the design optimization of a novel MR-brake, which incorporates a serpentine flux path and a permanent magnet. To the best of our knowledge, this is the first such MR-brake. The new MR-brake design provides a fail-safe feature while reducing the volume by decreasing the number of coil turns required. Results showed that some of the geometric parameters and the current have the most significant effect on the torque output out of the 12 design parameters.

Rubber Composition–Properties Relationships during Tire Numerical Simulation and Design Optimization

2017 ◽  
Vol 45 (1) ◽  
pp. 71-84 ◽  
Author(s):  
Alexey Mazin ◽  
Alexander Kapustin ◽  
Mikhail Soloviev ◽  
Alexander Karanets
Keyword(s):  
Numerical Simulation ◽  
Design Optimization ◽  
Strain Tensor ◽  
General Purpose ◽  
Orthogonal Functions ◽  
Element Analysis ◽  
Time Investment ◽  
Footprint Analysis ◽  
Composition Properties ◽  
Nonlinear Elastic

ABSTRACT Numerical simulation based on finite element analysis is now widely used during the design optimization of tires, thereby drastically reducing the time investment in the design process and improving tire performance because it is obtained from the optimized solution. Rubber material models that are used in numerical calculations of stress–strain distributions are nonlinear and may include several parameters. The relations of these parameters with rubber formulations are usually unknown, so the designer has no information on whether the optimal set of parameters is reachable by the rubber technological possibilities. The aim of this work was to develop such relations. The most common approach to derive the equation of the state of rubber is based on the expansion of the strain energy in a series of invariants of the strain tensor. Here, we show that this approach has several drawbacks, one of which is problems that arise when trying to build on its basis the quantitative relations between the rubber composition and its properties. An alternative is to use a series expansion in orthogonal functions, thereby ensuring the linear independence of the coefficients of elasticity in evaluation of the experimental data and the possibility of constructing continuous maps of “the composition to the property.” In the case of orthogonal Legendre polynomials, the technique for constructing such maps is considered, and a set of empirical functions is proposed to adequately describe the dependence of the parameters of nonlinear elastic properties of general-purpose rubbers on the content of the main ingredients. The calculated sets of parameters were used in numerical tire simulations including static loading, footprint analysis, braking/acceleration, and cornering and also in design optimization procedures.

Prediction of Tire Tread Wear with FEM Steady State Rolling Contact Simulation

2003 ◽  
Vol 31 (3) ◽  
pp. 189-202 ◽  
Author(s):  
D. Zheng
Keyword(s):  
Weight Loss ◽  
Steady State ◽  
Cross Section ◽  
Rolling Contact ◽  
Dynamic Simulations ◽  
Element Analysis ◽  
Vehicle Acceleration ◽  
Steady State Rolling ◽  
Driving Conditions ◽  
Rate Profile

Abstract A procedure based on steady state rolling contact Finite Element Analysis (FEM) has been developed to predict tire cross section tread wear profile under specified vehicle driving conditions. This procedure not only considers the tire construction effects, it also includes the effects of materials, vehicle setup, test course, and driver's driving style. In this algorithm, the vehicle driving conditions are represented by the vehicle acceleration histogram. Vehicle dynamic simulations are done to transform the acceleration histogram into tire loading condition distributions for each tire position. Tire weight loss rates for different vehicle accelerations are generated based on a steady state rolling contact simulation algorithm. Combining the weight loss rate and the vehicle acceleration histogram, nine typical tire loading conditions are chosen with different weight factors to represent tire usage conditions. It is discovered that the tire tread wear rate profile is changing continuously as the tire is worn. Simulation of a new tire alone cannot be used to predict the tire cross-section tread wear profile. For this reason, an incremental tread wear simulation procedure is performed to predict the tire cross section tread wear profile. Compared with actual tire cross-section tread wear profiles, good results are obtained from the simulations.

scholarly journals Modeling the Excess Velocity of Low-Viscous Taylor Droplets in Square Microchannels

Fluids ◽  
2019 ◽  
Vol 4 (3) ◽  
pp. 162 ◽  
Author(s):  
Thorben Helmers ◽  
Philip Kemper ◽  
Jorg Thöming ◽  
Ulrich Mießner
Keyword(s):  
High Speed ◽  
Process Intensification ◽  
Continuous Phase ◽  
Channel Cross Section ◽  
Optimization Approach ◽  
Mean Flow ◽  
Bypass Flow ◽  
Wall Film ◽  
Proposed Model ◽  
The Mean

Microscopic multiphase flows have gained broad interest due to their capability to transfer processes into new operational windows and achieving significant process intensification. However, the hydrodynamic behavior of Taylor droplets is not yet entirely understood. In this work, we introduce a model to determine the excess velocity of Taylor droplets in square microchannels. This velocity difference between the droplet and the total superficial velocity of the flow has a direct influence on the droplet residence time and is linked to the pressure drop. Since the droplet does not occupy the entire channel cross-section, it enables the continuous phase to bypass the droplet through the corners. A consideration of the continuity equation generally relates the excess velocity to the mean flow velocity. We base the quantification of the bypass flow on a correlation for the droplet cap deformation from its static shape. The cap deformation reveals the forces of the flowing liquids exerted onto the interface and allows estimating the local driving pressure gradient for the bypass flow. The characterizing parameters are identified as the bypass length, the wall film thickness, the viscosity ratio between both phases and the C a number. The proposed model is adapted with a stochastic, metaheuristic optimization approach based on genetic algorithms. In addition, our model was successfully verified with high-speed camera measurements and published empirical data.

scholarly journals Numerical and Theoretical Study of Performance and Mechanical Behavior of PEM-FC Using Innovative Channel Geometrical Configurations

2021 ◽  
Vol 11 (12) ◽  
pp. 5597
Author(s):  
Hussein A. Z. AL-bonsrulah ◽  
Mohammed J. Alshukri ◽  
Ammar I. Alsabery ◽  
Ishak Hashim
Keyword(s):  
Fuel Cell ◽  
Cross Section ◽  
Rectangular Channel ◽  
Compressive Load ◽  
Proton Exchange ◽  
Channel Cross Section ◽  
Channel Height ◽  
Cross Sectional ◽  
Triangular Channel ◽  
Higher Power

Proton exchange membrane fuel cell (PEM-FC) aggregation pressure causes extensive strains in cell segments. The compression of each segment takes place through the cell modeling method. In addition, a very heterogeneous compressive load is produced because of the recurrent channel rib design of the dipole plates, so that while high strains are provided below the rib, the domain continues in its initial uncompressed case under the ducts approximate to it. This leads to significant spatial variations in thermal and electrical connections and contact resistances (both in rib–GDL and membrane–GDL interfaces). Variations in heat, charge, and mass transfer rates within the GDL can affect the performance of the fuel cell (FC) and its lifetime. In this paper, two scenarios are considered to verify the performance and lifetime of the PEM-FC using different innovative channel geometries. The first scenario is conducted by adopting a constant channel height (H = 1 mm) for all the differently shaped channels studied. In contrast, the second scenario is conducted by taking a constant channel cross-sectional area (A = 1 mm2) for all the studied channels. Therefore, a computational fluid dynamics model (CFD) for a PEM fuel cell is formed through the assembly of FC to simulate the pressure variations inside it. The simulation results showed that a triangular cross-section channel provided the uniformity of the pressure distribution, with lower deformations and lower mechanical stresses. The analysis helped gain insights into the physical mechanisms that lead to the FC’s durability and identify important parameters under different conditions. The model shows that it can assume the intracellular pressure configuration toward durability and appearance containing limited experimental data. The results also proved that the better cell voltage occurs in the case of the rectangular channel cross-section, and therefore, higher power from the FC, although its durability is much lower compared to the durability of the triangular channel. The results also showed that the rectangular channel cross-section gave higher cell voltages, and therefore, higher power (0.63 W) from the fuel cell, although its durability is much lower compared to the durability of the triangular channel. Therefore, the triangular channel gives better performance compared to other innovative channels.

scholarly journals Flexural bearing capacity and failure mechanism of CFRP-aluminum laminate beam with double-channel cross-section

2021 ◽  
Vol 28 (1) ◽  
pp. 139-152
Author(s):  
Teng Huang ◽  
Dongdong Zhang ◽  
Yaxin Huang ◽  
Chengfei Fan ◽  
Yuan Lin ◽  
...  
Keyword(s):  
Carbon Fiber ◽  
Bearing Capacity ◽  
Failure Mechanism ◽  
Cross Section ◽  
Failure Criterion ◽  
Failure Modes ◽  
Channel Cross Section ◽  
Fiber Layer ◽  
Flexural Bearing Capacity ◽  
Double Channel

Abstract In this study, the flexural bearing capacity and failure mechanism of carbon fiber-reinforced aluminum laminate (CARALL) beams with a double-channel cross-section and a 3/2 laminated configuration were experimentally and numerically studied. Two types of specimens using different carbon fiber layup configurations ([0°/90°/0°]3 and [45°/0°/−45°]3) were fabricated using the pressure molding thermal curing forming process. The double-channel CARALL beams were subjected to static three-point bending tests to determine their failure behaviors in terms of ultimate bearing capacity and failure modes. Owing to the shortcomings of the two-dimensional Hashin failure criterion, the user-defined FORTRAN subroutine VUMAT suitable for the ABAQUS/Explicit solver and an analysis algorithm were established to obtain a progressive damage prediction of the CFRP layer using the three-dimensional Hashin failure criterion. Various failure behaviors and mechanisms of the CARALL beams were numerically analyzed. The results indicated that the numerical simulation was consistent with the experimental results for the ultimate bearing capacity and final failure modes, and the failure process of the double-channel CARALL beams could be revealed. The ultimate failure modes of both types of double-channel CARALL beams were local buckling deformation at the intersection of the upper flange and web near the concentrated loading position, which was mainly caused by the delamination failure among different unidirectional plates, tension and compression failure of the matrix, and shear failure of the fiber layers. The ability of each fiber layer to resist damage decreased in the order of 90° fiber layer > 0° fiber layer > 45° fiber layer. Thus, it is suggested that 90°, 0°, and 45° fiber layers should be stacked for double-channel CARALL beams.

Determination of collapse moment of different angled pipe bends with initial geometric imperfection subjected to in-plane bending moments

2021 ◽  
pp. 095440622199640
Author(s):  
Manish Kumar ◽  
Pronab Roy ◽  
Kallol Khan
Keyword(s):  
Finite Element ◽  
Cross Section ◽  
Circular Cross Section ◽  
Initial Imperfection ◽  
Bend Angle ◽  
Bending Moments ◽  
Element Analysis ◽  
Geometric Imperfection ◽  
Initial Geometric Imperfection

From the recent literature, it is revealed that pipe bend geometry deviates from the circular cross-section due to pipe bending process for any bend angle, and this deviation in the cross-section is defined as the initial geometric imperfection. This paper focuses on the determination of collapse moment of different angled pipe bends incorporated with initial geometric imperfection subjected to in-plane closing and opening bending moments. The three-dimensional finite element analysis is accounted for geometric as well as material nonlinearities. Python scripting is implemented for modeling the pipe bends with initial geometry imperfection. The twice-elastic-slope method is adopted to determine the collapse moments. From the results, it is observed that initial imperfection has significant impact on the collapse moment of pipe bends. It can be concluded that the effect of initial imperfection decreases with the decrease in bend angle from 150∘ to 45∘. Based on the finite element results, a simple collapse moment equation is proposed to predict the collapse moment for more accurate cross-section of the different angled pipe bends.

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