Experimental numerical method of loading estimation for structures with surface cracks

The theoretical basis of an experimental numerical method permitting the estimation of the loading of structures with surface cracks based on the mathematical processing of displacement fields caused by a small aperture drilling in the crack tip is presented. The methodical approaches allowing for the solution of the problem for structure elements in the form of plates and shells with through-thickness cracks and for solid components with semielliptical cracks are given. The problem is solved as an inverse problem of experimental mechanics where the values of the displacement caused by aperture drilling are known under unknown force boundary conditions. The problem is solved via objective function minimization (the objective function is the root-mean-square deviation of the experimentally determined displacements in N points of experimental data logging on the surface of the examined area from their calculated values obtained as a result of the direct problem solution).     

Numerical and experimental investigation on the diffuser optimization of a reactor coolant pump with orthogonal test approach

The diffuser of a reactor coolant pump was optimized using an orthogonal approach with numerical simulation to improve the pump hydraulic performance. Steady simulation was conducted by solving Reynolds-averaged Naiver-Stokes equations with the SST k-ω turbulence model using CFX code. The influence of the diffuser geometric parameters, namely, S, φ, α ₄, b ₄, δ ₂, R _t and R ₄, on the pump performance were determined. L₁₈ (3⁷) orthogonal table was chosen for the optimization process. Best indicators were determined, and range analysis of energy losses, head, and efficiency at the rated condition was performed. Optimal parameters of the diffuser were S = 490 mm, φ = 36°, α ₄ = 30°, b ₄ = 200 mm, δ ₂ = 20 mm, R _t = 5 mm and R ₄ = 565 mm. The final design was experimentally tested. Simulation results showed more remarkable performance than the experimental result. However, the numerical predictions and experimental results were consistent, validating the design procedure. Loading of the impeller and diffuser blades was analyzed to investigate the direct impact on the hydrodynamic flow field. The head was 14.74 m, efficiency was 79.6 %, and efficiency of the prototype pump was 83.3 % when the model pump functioned at the rated conditions. Optimization results showed that efficiency and head were improved at the design condition.     

Regressing sample quantiles to perform nonparametric capability analysis

Capability analysis corresponds to a set of methods used to estimate and test the ability of an in-control process to provide a specific output. When there is only one quality characteristic that behaves as a continuous random variable, indices like C_p and C_pk can be used to measure how well requirements are met. Under normality, variation is indicated using 3?sigma limits; otherwise, the corresponding quantiles are used. Distribution fitting and transformations to normality can be used to estimate quantiles by finding an overall fit to the data available. However, by giving the same weight to all observations, the best possible fit of extreme values can be lost. To address this issue, a regression approach is proposed to fit functions over maximum likelihood estimates of probabilities of extreme values. A case study from the automotive industry is used to illustrate the proposed approach. To evaluate the performance, extensive Monte Carlo simulation is used, and the results are compared with the corresponding approach using the Clements method. The proposed nonparametric technique shows smaller MAD when high levels of skewness exist. Practitioners with basic knowledge of regression analysis may find the approach useful to estimate capability indices without the need of a specific probability distribution.     

Nonuniform magnetization of an article around a flaw during magnetic inspection

Measurements of the induction in a ferromagnetic article directly around a surface flaw in the form of a rectangular slot have shown that there is a substantial magnetization nonuniformity of the article owing to the discontinuity. The nonuniformity smooths out as magnetizing field H ₀ increases. The increase in magnetizing field H ₀ increases the nonuniformity of the field distribution over the article surface, thereby changing the topography of the flaw field. In particular, in low magnetizing fields, this change leads to the absence of negative extrema in the curve of the tangential component of the flaw field, H _x (x). The discrepancy between the calculated and experimental values of the fields of flaws characterized by different geometric parameters is indicative of a considerable effect of the flaw opening on calculated data. These data should be improved through proper corrections obtained experimentally.     

Taguchi-based grey relational analysis for modeling and optimizing machining parameters through dry turning of Incoloy 800H

The present research focused on the optimization of machining parameters and their effects by dry-turning an incoloy 800H on the basis of Taguchi-based grey relational analysis. Surface roughness (Ra, Rq and Rz), cutting force (Fz), and cutting power (P) were minimized, whereas Material removal rate (MRR) was maximized. An L ₂₇ orthogonal array was used in the experiments, which were conducted in a computerized and numerical-controlled turning machine. Cutting speed, feed rate, and cut depth were set as controllable machining variables, and analysis of variance was performed to determine the contribution of each variable. We then developed regression models, which ultimately conformed to investigational and predicted values. The combinational parameters for the multiperformance optimization were V = 35 m/min, f = 0.06 mm/rev and a = 1 mm, which altogether correspond to approximately 48.98 % of the improvement. The chip morphology of the incoloy 800H was also studied and reported.     

Heat transfer in a turbulent jet impinging on a moving plate considering high plate-to-jet velocity ratios

In this paper, heat transfer characteristics of a turbulent slot jet impinging orthogonally on an isothermal moving hot plate is studied numerically. The governing equations were discretized using the finite volume method and the υ ² — f turbulence model was employed for turbulence modeling. The effect of the jet Reynolds number and the plate-to-jet velocity ratio (R) on the Nusselt were investigated. Despite of most previous studies, which have been restricted to R≤2, in the present research higher values of R, also were considered (0≤R≤6). Range of studied jet Reynolds number was between 3000 and 60000. The results indicate that at a fixed plate-to-jet velocity ratio increment of the Reynolds number leads to the enhancement of the average Nusselt number. For each Reynolds number, the average Nusselt number reduces with increasing the plate-to-jet velocity ratio until it becomes minimum at R = 1.25. For R>1.25 trend changes so that these parameters increase. In addition, it was found that only for R>2.5 the average Nusselt number is improved due to the plate motion in comparison with the stationary jet. The results are validated against available experimental data, showing good agreement.     

Integrated ANN-LWPA for cutting parameter optimization in WEDM

In this paper, we present a new approach to determinate cutting parameters in wire electrical discharge machining (WEDM), integrated artificial neuron network (ANN), and wolf pack algorithm based on the strategy of the leader (LWPA). The cutting parameters considered in this paper are pulse-on, current, water pressure, and cutting feed rate. Models of the effects of the four parameters on machining time (T_p), machining cost (C_p), and surface roughness (Ra) are mathematically constructed. An ANN-LWPA integration system with multiple fitness functions is proposed to solve the modelling problem. By using the proposed approach, this study demonstrates that T_p, C_p, and Ra can be estimated at 164.1852 min, 239.5442 RMB, and 1.0223 μm in single objective optimization, respectively. For example, as for Ra, integrated ANN-LWPA has optimized the Ra value by the reduction of 0.1337 μm (11.6 %), 0.3377 μm (24.8 %), and 0.105 μm (10.3 %) compared to experimental data, regression model, and ANN model, respectively. Consequently, the ANN-LWPA integration system boasts some advantages over decreasing the value of fitness functions by comparison with the experimental regression model, ANN model, and conventional LWPA result. Moreover, the proposed integration system can be also utilized to obtain multiple solutions by uniform design-based exploration. Therefore, in order to solve complex machining optimization problems, an intelligent process scheme could be integrated into the numeric control system of WEDM.     

Optimization on the impeller of a low-specific-speed centrifugal pump for hydraulic performance improvement

In order to widen the high-efficiency operating range of a low-specific-speed centrifugal pump, an optimization process for considering efficiencies under 1.0Q_d and 1.4Q_d is proposed. Three parameters, namely, the blade outlet width b_2, blade outlet angle β_2, and blade wrap angle φ, are selected as design variables. Impellers are generated using the optimal Latin hypercube sampling method. The pump efficiencies are calculated using the software CFX 14.5 at two operating points selected as objectives. Surrogate models are also constructed to analyze the relationship between the objectives and the design variables. Finally, the particle swarm optimization algorithm is applied to calculate the surrogate model to determine the best combination of the impeller parameters. The results show that the performance curve predicted by numerical simulation has a good agreement with the experimental results. Compared with the efficiencies of the original impeller, the hydraulic efficiencies of the optimized impeller are increased by 4.18% and 0.62% under 1.0Q_d and 1.4Q_d, respectively. The comparison of inner flow between the original pump and optimized one illustrates the improvement of performance. The optimization process can provide a useful reference on performance improvement of other pumps, even on reduction of pressure fluctuations.     

Implementation of design of experiment for structural optimization of annular jet pumps

The DOE (Design of experiments) method together with CFD (Computational fluid dynamics) was applied to optimize structural combination of the Annular jet pumps (AJPs). An AJP with an area ratio of 1.75 was selected as the simulation prototype and the numerical results were validated by experiments. According to the DOE method, four impact factors were selected for simulation. The results showed that two-factor’s reciprocal action is more applicable than that of single factor on the AJP’s performance, especially the two groups, α*l _t and l _t*β, respectively. The structure of AJPs with different area ratios ranging from 1.5 to 40 were optimized by the DOE method. The corresponding optimum structural parameters and performance curves were plotted to acquire the performance envelope lines, the efficiency envelope line and the peak efficiency lines, which are useful for AJP’s structure design and obtaining its operation condition.     

Numerical investigation on the influence of surface tension and viscous force on the bubble dynamics with a CLSVOF method

We numerically investigated the rising of bubbles in a quiescent liquid layer. The numerical simulation is performed by solving the incompressible, multiphase Navier-Stokes equations via computational code in axisymmetric coordinates using a Coupled level-set and volume-of-fluid (CLSVOF) method. The numerical results show that the CLSVOF method with a novel algebraic relation between F and ? for axisymmetric two-phase flows not only can predict the bubble surface accurately, but also overcome the deficiency in preserving volume conservation. The effects of the Reynolds number Re and the Bond number Bo on the bubble deformation and its motion are investigated. The results show that with the increasing of Re (10 < Re < 150), the bubble shape transfers from oblate ellipsoidal cap to toroidal when Bo = 116. With the increasing of Bo (10 < Bo < 700), the bubble shape transfers from oblate ellipsoidal to toroidal when Re = 30. Although the toroidal bubble shapes are reached in these two cases, the transition modes are different. For the case Bo = 116, the bubble front is pierced by an upward jet from the rear of the bubble. While for the case Re = 30, the rear of the bubble is pierced by a downward jet from the front part.     

Application of different surrogate models on the optimization of centrifugal pump

An optimization process for impellers was carried out based on numerical simulation, Latin hypercube sampling (LHS), surrogate model and Genetic algorithm (GA) to improve the efficiency of residual heat removal pump. The commercial software ANSYS CFX 14.5 was utilized to solve the Reynolds-averaged Navier-Stokes equations by using the Shear stress transport turbulence model. The impeller blade parameters, which contain the blade inlet incidence angle Δβ, blade wrap angle φ, and blade outlet angle β ₂, were designed by random sample points according to the LHS method. The efficiency predicted under the design flow rate was selected as the objective function. The best combination of parameters was obtained by calculating the surrogate model with the GA. Meanwhile, the prediction accuracies of three surrogate models, namely, Response surface model (RSM), Kriging model, and Radial basis neural network (RBNN), were compared. Results showed that the calculated findings agree with the experimental performance results of the original pump. The RSF model predicted the highest efficiency, while the RBNN had the highest prediction accuracy. Compared with the simulated efficiency of the original pump, the optimization increased efficiency by 8.34% under the design point. Finally, the internal flow fields were analyzed to understand the mechanism of efficiency improvement. The optimization process, including the comparison of the surrogate models, can provide reference for the optimization design of other pumps.     

Geometry simulation and evaluation of the surface topography in five-axis ball-end milling

Limited by the factors such as dynamic vibrations, cutting heat, and the use of coolant, it is difficult to measure or evaluate the surface quality in real time. Geometry simulation of the surface topography became the main method used in engineering to estimate and control the quality of the surface machining. This paper proposed a new method for geometry simulation and evaluation of a milled surface. Allowing for the coherency in geometric variations management process, the proposed method is developed based on the skin model of a workpiece. To make the simulated surface topography more realistic, the effects of locating errors, spindle errors, geometrical errors of the machine tool, and cutting tool deflections are included. And a new method is adopted to evaluate the milled surface, in which the roughness of the surface is characterized by the modal coefficients, instead of the R _a , R _z , and R _q values. At the end of this paper, measurements and cutting tests are carried out to validate the proposed method.     

Effect of circular cylinder location on three-dimensional natural convection in a cubical enclosure

This paper presents the results of immersed boundary method-based three-dimension numerical simulations of natural convection in a cubical enclosure with an inner circular cylinder at a Prandtl number of 0.7. This simulation spans three decades of Rayleigh number, Ra, from 10³ to 10⁶. The location of the inner circular cylinder is changed vertically along the centerline of the cubical enclosure. This study primarily focuses on the effects of both buoyancy-induced convection and the location of the inner circular cylinder on heat transfer and fluid flow in the cubical enclosure. In the range of Rayleigh numbers considered in this study, the thermal and flow fields eventually reach steady state, regardless of the location of the inner cylinder. When Ra is 10³, the end wall of the cubical enclosure has a negligible effect on the thermal and flow fields in the enclosure. However, in the range of 10⁴ ≤ Ra ≤ 10⁶, the effect of the end wall on heat transfer and fluid flow in the enclosure depends on both the location of the inner cylinder and the Rayleigh number. Detailed analysis results for the distribution of streamlines, isotherms, and Nusselt numbers are presented in this paper.     

Computer-assisted methods for finding pulsed magnetic-field distributions near current-conducting objects

Time dependences are given for an electric voltage U(t) that is recorded across an inductive magnetic head when scanning a discontinuous magnetic carrier that has been subjected to pulsed magnetic fields of a linear inductor. The value of U(t) at each point of the carrier is determined by the amplitude of each pulse, the pulse direction, and the sequence of exposures. If a current-conducting object is present, this value also depends on the field pulse rise time. The phenomenon of hysteretic interference of a pulsed magnetic field (HI) is used. Digital images of pulsed magnetic fields, as well as computer-assisted methods for measuring these fields, finding their distributions, and processing observation results are presented.     

Parametric optimization of CNC turning process for hybrid metal matrix composite

Machining of hybrid metal matrix composite is difficult as the particulates are abrasive in nature and they behave like a cutting edge during machining resulting in quick tool wear and induces vibration. An attempt was made in this experimental study to evaluate the machining characteristics of hybrid metal matrix composite, and a mathematical model was developed to predict the responses, namely surface finish, intensity of vibration and work-tool interface temperature for known cutting condition while machining was performed in computer numerical control lathe. Design of experiments approach was used to conduct the trials; response surface methodology was employed to formulate a mathematical model. The experimental study inferred that the vibration in V _x, V _y, and V _z were 41.59, 45.17, and 26.45 m/s², respectively, and surface finish R _a, R _q, and R _z were 1.76, 3.01, and 11.94 μm, respectively, with work-tool interface temperature ‘T’ of 51.74 °C for optimal machining parameters, say, cutting speed at 175 m/min, depth of cut at 0.25 mm and feed rate at 0.1 mm/rev during machining. Experimental results were in close conformity with response surface method overlay plot for responses.     

Fast design of the QP-based optimal trajectory for a motion simulator

The main difficulty in realizing a motion simulator comes from the constraints on its workspace. The so-called washout filter prevents a simulator from being driven to go off its pre-determined boundaries and generate excessive torques. By noting that the existing washout filters are conservative and more aggressive motions may be accommodated, this paper presents a novel approach that fully exploits the simulator workspace and thereby reproduces the real-world sensations with high fidelity. The washout filter converts the real-world input trajectory as a realizable one that satisfies the spatial and dynamic constraints while minimizing the sensation error and fidelity between the motions experienced in the real world and on the motion simulator. The control objective is to reduce the computational burdens by using the QP algorithm. The proposed approach formulates the task of designing a washout filter as a quadratic programming (QP). The direct approach to the solution of the QP often results in a computational burden that amounts toO(N ³) flops andO(N ²) storage space (N=10⁴ ～ 10⁵, typically). By judiciously exploiting the Toeplitz structures of the underlying matrices, an orders-of-magnitude faster algorithm is obtained to reduce the computational burdens toO(Nlog₂ N) flops andO(N) storage space. The extensive simulation studies on the Eclipse-II motion simulator at Seoul National University assure that the QP-based fast algorithm outperforms the existing ones in reproducing the real-world sensations.     

Input fault detection and estimation using PI observer based on the ARX-Laguerre model

This work is dedicated to the synthesis of a new fault detection and identification scheme for the actuator and/or sensor faults modeled as unknown inputs of the system. The novelty of this scheme consists in the synthesis of a new structure of proportional-integral observer (PIO) reformulated from the new linear ARX-Laguerre representation with filters on system input and output in order to estimate the unknown inputs presented as faults. The designed observer exploits the input/output measurements to reconstruct the Laguerre filter outputs where the stability and the convergence properties are ensured by using Linear Matrix Inequality. However, a significant reduction of this model is subject to an optimal choice of both Laguerre poles which is achieved by a new proposed identification approach based on a genetic algorithm. The performances of the proposed identification approach and the resulting PIO are tested on numerical simulation and validated on a 2 ^{n d} order electrical linear system.     

The use of new resonance integrals for determining the parameters of the epithermal neutron spectrum

A simple method for determining parameters α and b in the presentation of the epithermal neutron spectrum in the form of φ_epi(E) = b/E ^{1 + α} using expansion of function φ_epi(E) in Taylor series with respect to parameter α is described. The problem of determining the parameters is reduced to finding a solution to a system of algebraic equations. The approximation used describes the spectrum with an adequate accuracy up to energies of ～1–50 keV, depending on value α ～ 0.2?0.1, with the help of the first two or three expansion terms (resonance integrals), respectively. The first two resonance integrals for reactions ¹⁹⁷Au(n, γ)¹⁹⁸Au and ⁵⁵Mn(n, γ)⁵⁶Mn are estimated. The measured rates of the appropriate reactions and the values of parameters α and b for the case of an assembly with a graphite moderator are presented.     

A method for measuring spectral and time characteristics of mixed pulsed gamma-neutron fields with scintillation and Cherenkov detectors with nanosecond time resolution

A method for measuring spectral and time characteristics of pulsed mixed (n, γ) fields is described. The essence of this method is that a sequence of signals from individual (n, γ) particles registered by (n, γ) detectors is written in a computer with the subsequent amplitude-time analysis of the signal parameters. Fast scintillation and Cherenkov detectors with FWHM of pulses of ～1.5 and 2.5 ns, respectively, are used as (n, γ) detectors. A TDS-3054 broadband digital oscilloscope records signals and transmits them to the computer through a GPIB-USB interface. The equipment used ensures efficient detection of (n, γ) particles at detector counting rates of up to ～2 × 10⁸ pulses/s. The efficiency of this method has been tested in measurements of characteristics of (n, γ) radiation fields from an ИНГ-031 pulsed neutron generator and from a copper target irradiated with a beam of carbon nuclei with an energy of 200 MeV/amu from the TVN-ITEF acceleration-storage complex.     

Numerical Analysis and Verification of the Gas Jet from Aircraft Engines Impacting a Jet Blast Deflector

The process of the gas jet from aircraft engines impacting a jet blast deflector is not only a complex fluid–solid coupling problem that is not easy to compute, but also a safety issue that seriously interferes with flight deck environment. The computational fluid dynamics (CFD) method is used to simulate numerically the impact effect of gas jet from aircraft engines on a jet blast deflector by using the Reynolds-averaged Navier-Stokes (RANS) equations and turbulence models. First of all, during the pre-processing of numerical computation, a sub-domains hybrid meshing scheme is adopted to reduce mesh number and improve mesh quality. Then, four different turbulence models including shear-stress transport (SST) k-w, standard k-w, standard k-ε and Reynolds stress model (RSM) are used to compare and verify the correctness of numerical methods for gas jet from a single aircraft engine. The predicted values are in good agreement with the experimental data, and the distribution and regularity of shock wave, velocity, pressure and temperature of a single aircraft engine are got. The results show that SST k-w turbulence model is more suitable for the numerical simulation of compressible viscous gas jet with high prediction accuracy. Finally, the impact effect of gas jet from two aircraft engines on a jet blast deflector is analyzed based on the above numerical method, not only the flow parameters of gas jet and the interaction regularity between gas jet and the jet blast deflector are got, but also the thermal shock properties and dynamic impact characteristics of gas jet impacting the jet blast deflector are got. So the dangerous activity area of crew and equipments on the flight deck can be predicted qualitatively and quantitatively. The proposed research explores out a correct numerical method for the fluid–solid interaction during the impact process of supersonic gas jet, which provides an effective technical support for design, thermal ablation and structural damage analysis of a new jet blast deflector.