Efficient warpage optimization of thin shell plastic parts using response surface methodology and genetic algorithm

During the production of thin shell plastic parts by injection molding, warpage depending on the process conditions is often encountered. In this study, efficient minimization of warpage on thin shell plastic parts by integrating finite element (FE) analysis, statistical design of experiment method, response surface methodology (RSM), and genetic algorithm (GA) is investigated. A bus ceiling lamp base is considered as a thin shell plastic part example. To achieve the minimum warpage, optimum process condition parameters are determined. Mold temperature, melt temperature, packing pressure, packing time, and cooling time are considered as process condition parameters. FE analyses are conducted for a combination of process parameters organized using statistical three-level full factorial experimental design. The most important process parameters influencing warpage are determined using FE analysis results based on analysis of variance (ANOVA) method. A predictive response surface model for warpage data is created using RSM. The response surface (RS) model is interfaced with an effective GA to find the optimum process parameter values.     

Development of RSM- and ANN-based models to predict and analyze the effects of process parameters of laser-hardened commercially pure titanium on heat input and tensile strength

Laser transformation hardening (LTH) is an innovative and advanced laser surface modification technique as compared to conventional transformation hardening processes and has been employed in aerospace, marine, chemical applications, heat exchangers, cryogenic vessels, components for chemical processing and desalination equipment, condenser tubing, airframe skin, and nonstructural components which introduces the advantageous residual stresses into the surface, improving the mechanical properties like wear, resistance to corrosion, tensile strength, and fatigue strength. In the present study, LTH of commercially pure titanium, nearer to ASTM grade 3 of chemical composition was investigated using continuous wave 2 kW, Nd: YAG laser. The effect of laser process variables such as laser power, scanning speed, and focused position was investigated using response surface methodology (RSM) and artificial neural network (ANN) keeping argon gas flow rate of 10 lpm as fixed input parameter. This paper describes the comparison of the heat input (HI) and ultimate tensile strength (σ) (simply called as tensile strength) predictive models based on ANN and RSM. The paper also presents the effect of laser process variables on the HI and ultimate σ. The research work also emphasizes on the effect of HI on σ. The experiments were conducted based on a three-factor, three-level Box–Behnken surface statistical design. Quadratic polynomial equations were developed for proper process parametric study for its optimal performance characteristics. The experimental results under optimum conditions were compared with the simulated values obtained from the RSM and ANN model. Adequacy of the developed models was tested by analysis of variance technique. A multilayer feed-forward neural network with a Levenberg–Marquardt back-propagation algorithm was adopted to develop the relationships between the laser hardening process parameters, HI, and ultimate σ. The performance of the developed ANN models were compared with the second-order RSM mathematical models of HI and σ. There was good agreement between the experimental and simulated values of RSM and ANN. The comparison clearly indicates that the ANN models provide more accurate prediction compared to the RSM models. It has been found that there is a trend of increased tensile strength with the decrease of hardening heat input and a trend of increased tensile strength with the increase of hardening cooling rate. As heat input decreases, there will be a faster cooling rate. Considering the effect of HI on ultimate σ, it was found that the lower the heat input, the faster cooling rate. The details of experimentation, model development, testing, validation of models, effect of laser process variables on heat input and ultimate σ, effect of HI on σ, and performance comparison of RSM and ANN models are presented in the paper. The results of Box–Behnken design of RSM and ANN models also indicate that the proposed models predict the responses adequately within the limits of input parameters being used. It is suggested that regression equations can be used to find optimum conditions for HI and σ of laser-hardened commercially pure titanium material.     

A comparative study of the ANN and RSM modeling approaches for predicting burr size in drilling

This paper describes the comparison of the burr size predictive models based on artificial neural networks (ANN) and response surface methodology (RSM). The models were developed based on three-level full factorial design of experiments conducted on AISI 316L stainless steel work material with cutting speed, feed, and point angle as the process parameters. The ANN predictive models of burr height and burr thickness were developed using a multilayer feed forward neural network, trained using an error back propagation learning algorithm (EBPA), which is based on the generalized delta rule. The performance of the developed ANN models were compared with the second-order RSM mathematical models of burr height and thickness. The comparison clearly indicates that the ANN models provide more accurate prediction compared to the RSM models. The details of experimentation, model development, testing, and performance comparison are presented in the paper.     

空调冷却塔变流量的优化研究

研究了冷却塔在优化状态下,优化风量和水流量随冷却塔负荷和室外空气状态的变化而变化的规律.得出在负荷从170kW降低到120kW时,冷却塔的优化风量降低为原来的54.6%,优化水流量为原来的70.6%,且考虑到室外温度降低4℃时,优化风量降为额定风量的22.6%,从理论上分析了变流量系统的节能性.     

Pilot-scale cooling tower to evaluate corrosion, scaling, and biofouling control strategies for cooling system makeup water

Pilot-scale cooling towers can be used to evaluate corrosion, scaling, and biofouling control strategies when using particular cooling system makeup water and particular operating conditions. To study the potential for using a number of different impaired waters as makeup water, a pilot-scale system capable of generating 27,000 kJ∕h heat load and maintaining recirculating water flow with a Reynolds number of 1.92 × 10(4) was designed to study these critical processes under conditions that are similar to full-scale systems. The pilot-scale cooling tower was equipped with an automatic makeup water control system, automatic blowdown control system, semi-automatic biocide feeding system, and corrosion, scaling, and biofouling monitoring systems. Observed operational data revealed that the major operating parameters, including temperature change (6.6 °C), cycles of concentration (N = 4.6), water flow velocity (0.66 m∕s), and air mass velocity (3660 kg∕h m(2)), were controlled quite well for an extended period of time (up to 2 months). Overall, the performance of the pilot-scale cooling towers using treated municipal wastewater was shown to be suitable to study critical processes (corrosion, scaling, biofouling) and evaluate cooling water management strategies for makeup waters of complex quality.     

复合地源热泵系统土壤换热器预测模型研究

在复合式地源热泵系统中控制策略存在着极大的优化空间,本文提出以土壤换热器与冷却塔两者出口水温作为控制依据的运行策略,为实现此控制方法,需要建立准确的预测模型.本文运用人工神经网络(ANN)实现土壤换热器侧出口水温的预测,研究复合式地源热泵系统不同运行模式下预测的可行性与准确性,并与动态数值模拟结果比较.结果表明利用人工神经网络可以准确预测土壤换热器的出口水温,且模型具有较好的泛华能力,最大误差不超过0.25℃.     

降低微型气相色谱仪检测器电路板工作温度的实验结果

在解决新设计的微型气相色谱仪检测器电路板工作温度较高的问题时,试图用强制风冷改善仪器机箱内的散热状况,并对此进行了仿真计算。但在实验过程中发现,加强风冷会导致模块运行时基线产生波动,进一步实验发现,这是因为加强风冷破坏了原有模块温度控制PID的条件所致。因此在本例中,强制风冷是不可行的。经仔细研究和测量,采用了两种新措施,一是将屏蔽盒下的变压器改换成电源芯片,二是在ADC引脚背面加上散热片。新措施成功地降低了电路板的工作温度。     

闭式冷却塔的数值分析

采用已有的数学模型,利用不同作者试验所得的传热、传质系数经验公式,预测了闭式冷却塔的热力性能,得到了不同工况下的出口温度、换热量,并与Hasan的试验测试结果进行对比,采用Mizushina的经验公式得到的预测换热量与试验值的最大偏差达到37.12%,采用Hasan试验所得的经验公式计算得到的结果与试验结果一致性较好。结果表明:预测闭式冷却塔不同工况下的热力性能时,应采用试验范围内所得的传热、传质系数经验公式,否则会产生较大误差。对闭式冷却塔热力性能的合理预测有一定的指导作用。     

干盘管系统冷冻水流量调节试验研究

通过对独立新风加干式风机盘管空调系统在不同室外工况下的试验研究,分析了冷冻水流量调节对空调系统性能及室内温湿度影响。结果表明,随冷冻水流量增加,系统提供的显热制冷量及潜热制冷量增加,而提供的冷量显热比减少;当冷冻水不能满足新风机组制冷要求时,增加水流量可以明显降低室内冷量显热比,在冷冻水流量满足新风机组制冷要求的基础上增加水流量,对新风机组的制冷量及室内显热比的影响不大;增加冷冻水流量对室内温度影响较大,而对室内相对湿度影响较小。     

逆顺流式与逆流式无填料喷雾冷却塔的试验研究

根据雾化冷却原理,建立了逆顺流式无填料喷雾冷却塔和逆流式无填料喷雾冷却塔,在介绍了30t/h试验用逆顺流式和逆流式无填料喷雾冷却塔的结构和性能的基础上,通过试验对两种冷却塔的冷却性能进行了研究,试验结果表明:当设计风量相同时,逆流式无填料喷雾冷却塔的实测风量比逆顺流式无填料喷雾冷却塔的实测风量大5.5%;在试验工况基本相同的条件下,逆流式无填料喷雾冷却塔的进出水温差较逆顺流式无填料喷雾冷却塔大0.5℃,逼近度约小0.9℃,冷却效率大20%,且其冷却效率最大值为53.4%.     

基于毛细管空调系统的试验研究

以能源与动力工程实验中心节能减排实验室为背景,对毛细管空调系统进行制冷及除湿实验。监测室内温湿度在水平和垂直方向上的温湿度分布情况;并且通过实验确定毛细管重力循环空调柜除湿和换热性能的影响因素及其最佳运行工况。结果表明:在人体的高度范围1.6².0m之间,室内温度维持在26.5℃左右,对人体非常适宜;供水流量在6002.0m之间,室内温度维持在26.5℃左右,对人体非常适宜;供水流量在600⁷00L/h,供水温度在17.5700L/h,供水温度在17.5¹8℃时,进出口空气温差增长的速度最快,重力循环空调柜换热经济性最佳;供水流量在50018℃时,进出口空气温差增长的速度最快,重力循环空调柜换热经济性最佳;供水流量在500⁶00L/h,供水温度在15.5600L/h,供水温度在15.5¹6℃时,出口空气流速增长的速度最快,重力循环空调柜除湿经济性最佳。     

THERMAL DESIGN FOR HARMON DRY-COOLING SYSTEM IN LARGE POWER STATION

Based on the analysis of air flow and heat transfer in the dry-cooling tower for Harmon system, a combined iteration method is presented to solve the coupled heat transfer and draft equations derived from theoretical and empirical formulas, with the size of the exchangers and the cooling tower or the systematic parameters being determined. Taking the 686 MW unit as an example, the present calculating results are well agreed with those of the real case, and thus the method presented is practical and feasible for reasonable design of Harmon system.     

Analysis of shrinkage and warpage in an injection-molded part with a thin shell feature using the response surface methodology

This paper presents a systematic methodology to analyze the shrinkage and warpage in an injection-molded part with a thin shell feature during the injection molding process. The systematic experimental design based on the response surface methodology (RSM) is applied to identify the effects of machining parameters on the performance of shrinkage and warpage. The experiment plan adopts the centered central composite design (CCD). The quadratic model of RSM associated sequential approximation optimization (SAO) method is used to find the optimum value of machining parameters. One real case study in the injection molding process of polycarbonate/acrylonitrile butadiene styrene (PC/ABS) cell phone shell has been performed to verify the proposed optimum procedure. The mold temperature (M _T), packing time (P _t), packing pressure (P _P) and cooling time (C _t) in the packing stage are considered as machining parameters. The results of analysis of variance (ANOVA) and conducting confirmation experiments demonstrate that the quadratic models of the shrinkage and warpage are fairly well fitted with the experimental values. The individual influences of all machining parameters on the shrinkage and warpage have been analyzed and predicted by the obtained mathematical models. For the manufacture of PC/ABS cell phone shell, the values of shrinkage and warpage present the reduction of 37.8 and 53.9%, respectively, using this optimal procedure.     

空调用封闭式冷却塔空气动力特性的实验研究

建立了由锅炉、换热器、孔板流量计、水泵、微压计、温度计等仪器设备组成的封闭式冷却塔实验台。在该实验台上详细测试了在封闭式冷却塔内空气与水逆向流动条件下,空气流经冷却盘管的阻力,探讨了封闭式冷却塔内空气的流动规律,分析了空气流过正三角排列管束的特性。建立了空气流动阻力的准则方程,即欧拉数Eu与雷诺数Re、普朗特数Pr之间的函数关系。利用这个准则方程可以方便地计算空气流经冷却盘管的阻力,合理地选配封闭式冷却塔所用风机和设计冷却盘管的管间距。     

某相控阵雷达天线阵面的热设计与验证

为了解决某高热流密度相控阵雷达天线阵面的散热问题,文中采用强迫通风冷却的散热方式,在天线阵面热设计中使用了高效换热的风–风换热器和高导热热管,满足了天线阵面组件壳体温度要求。同时,在设计天线阵面流场时,采用了内外风道隔离、内循环风道风机并联的送风方式,满足了天线阵面组件壳体的均温性要求。最后通过数值仿真和搭建平台测试两种方法,验证了该热设计方案的可行性。     

冷却塔风筒内流速场分布的研究

在分析冷却塔构成的基础上，建立了描述冷却冷却塔风筒内流场分布的数学模型，进而利用MATLAB语言求出了偏微分方程组的数值解，绘出了风筒内的流场。经研究发现，在风筒的中心处，存在一个空气倒吸的区域。最后，提出了消除空气倒吸现象的措施。     

基于CFD的锂离子动力电池箱散热分析

建立了锂离子电池的热特性模型,将电池内部复杂的层状结构当作一种均质的各向异性材料,求得电池的平均热特性参数.利用ANSYS ICE-PAK计算流体动力学软件对强迫风冷电池箱内的流场和温度场进行了仿真分析,并且对通风冷却方案进行了优化.同时研究了放电倍率、风扇风量和风道尺寸等因素对电池箱温度场的影响.     

Modeling and analyzing the effects of air-cooled turning on the machinability of Ti–6Al–4V titanium alloy using the cold air gun coolant system

This study provides the mathematical models for modeling and analyzing the effects of air-cooling on the machinability of Ti–6Al–4V titanium alloy in the hard turning process. A cold air gun coolant system was used in the experiments and produced a jet of compressed cold air for cooling the cutting process. The air-cooling process seems to be a good environment friendly option for the hard turning. In this experimental investigation, the cutting speed, feed rate and cutting depth were chosen as the numerical factor; the cooling method was regarded as the categorical factor. An experimental plan of a four-factor (three numerical plus one categorical) D-optimal design based on the response surface methodology (RSM) was employed to carry out the experimental study. The mathematical models based on the RSM were proposed for modeling and analyzing the cutting temperature and surface roughness in the hard turning process under the dry cutting process and air-cooling process. Tool wear and chip formation during the cutting process were also studied. The compressed cooling air in the gas form presents better penetration of the lubricant to the cutting zone than any conventional coolants in the cutting process do. Results show that the air-cooling significantly provides lower cutting temperature, reduces the tool wear, and produces the best machined surface. The machinability performance of hard turning Ti–6Al–4V titanium alloy on the application of air-cooling is better than the application of dry cutting process. This air-cooling cutting process easily produces the wrinkled and breaking chips. Consequently, the air-cooled cutting process offers the attractive alternative of the dry cutting in the hard turning process.     

The effect of cooling conditions on convective heat transfer and flow in a steam-cooled ribbed duct

This work presents a numerical and experimental investigation on the heat transfer and turbulent flow of cooling steam in a rectangular duct with 90° ribs and studies the effect of cooling conditions on the heat transfer augmentation of steam. In the calculation, the variation range of Reynolds is from 10,000 to 190,000, the inlet temperature varies from 300°C to 500°C and the outlet pressure is from 0.5MPa to 6MPa. The aforementioned wide ranges of flow parameters cover the actual operating condition of coolant used in the gas turbine blades. The computations are carried with four turbulence models (the standard k-?, the renormalized group (RNG) k-?, the Launder-Reece-Rodi (LRR) and the Speziale-Sarkar-Gatski (SSG) turbulence models). The comparison of numerical and experimental results reveals that the SSG turbulence model is suitable for steam flow in the ribbed duct. Therefore, adopting the conjugate calculation technique, further study on the steam heat transfer and flow characteristics is performed with SSG turbulence model. The results show that the variation of cooling condition strongly impacts the forced convection heat transfer of steam in the ribbed duct. The cooling supply condition of a relative low temperature and medium pressure could bring a considerable advantage on steam thermal enhancement. In addition, comparing the heat transfer level between steam flow and air flow, the performance advantage of using steam is also influenced by the cooling supply condition. Changing Reynolds number has little effect on the performance superiority of steam cooling. Increasing pressure would strengthen the advantage, but increasing temperature gives an opposite result.     

闭式冷却塔空冷传热性能的试验研究及优化运行

搭建了扭曲管闭式冷却塔的换热实验平台,在空冷模式下通过测试在不同风机频率以及风机频率固定时不同的管内流体进口温度、空气干球温度情况下闭塔的传热性能、流动阻力和能耗,得到了风机频率、管程体积流量以及管程进口温度、环境温度对综合传热性能和空冷传热量的影响,进而得出优化闭塔空冷换热的方式,并推导出在不同的季节温度下最合理的运行方式。同时本试验拟合了风机频率和风机功率等与迎面风速的试验关联式以及空冷管外空气的传热系数试验关联式,对扭曲管式闭式冷却塔的优化设计有一定的指导作用。