Shrinkage compensation approach proposed for ABS material in FDM process

Dimensional accuracy of parts manufactured by Fused Deposition Modelling (FDM) greatly suffers from the shrinkage problems of the available polymer materials. This paper proposes a constructive idea for resolving the shrinkage issues and explains how shrinkage could be managed by interior geometry of the artifacts fabricated on desktop 3D printers. The main principle for preventing the deterioration on dimensional accuracy of the holes/slots is to utilize the auxiliary lines located from the hole’s perimeter to the outer boundaries of the artifact. Thus, the shrinkage of these auxiliary line segments simply helps to pull the original hole backward, acting against the predicted contraction. In this paper, the proposed approach will be examined using a finite element analysis tool to predict the shrinkage behavior of the fabricated samples along with necessary measurements taken on the Coordinate Measuring Machine. Additionally, an analytical framework for modeling the shrinkage behavior of ABS is to be elaborated. The coherence of the simulations and the measurements are to be analyzed regarding the effect of the geometry and material color on the shrinkage behavior. The discussion involves the improvement on the dimensional accuracy of 3D printed features.     

Insertion of triangulated surfaces into a meccano tetrahedral discretization by means of mesh refinement and optimization procedures

In this paper, we present a new method for inserting several triangulated surfaces into an existing tetrahedral mesh generated by the meccano method. The result is a conformal mesh where each inserted surface is approximated by a set of faces of the final tetrahedral mesh. First, the tetrahedral mesh is refined around the inserted surfaces to capture their geometric features. Second, each immersed surface is approximated by a set of faces from the tetrahedral mesh. Third, following a novel approach, the nodes of the approximated surfaces are mapped to the corresponding immersed surface. Fourth, we untangle and smooth the mesh by optimizing a regularized shape distortion measure for tetrahedral elements in which we move all the nodes of the mesh, restricting the movement of the edge and surface nodes along the corresponding entity they belong to. The refining process allows approximating the immersed surface for any initial meccano tetrahedral mesh. Moreover, the proposed projection method avoids computational expensive geometric projections. Finally, the applied simultaneous untangling and smoothing process delivers a high‐quality mesh and ensures that the immersed surfaces are interpolated. Several examples are presented to assess the properties of the proposed method.     

Flow calorimeter for enthalpy increment measurements on condensed gases

A flow calorimeter for enthalpy increment measurements on condensed gases is presented. A better knowledge of the properties of the liquefied natural gas is needed, and therefore a liquid loop has been designed for our flow calorimeter. The fluid loop in the calorimeter is designed in order to avoid the two-phase region, since two phases would give compositional disturbances in the measurements. The avoidance of the two-phase region is made possible by increasing the pressure of the test fluid after the measurement section, then heating the fluid at super-critical pressure past the critical point. Finally, the fluid is throttled to the low-pressure gas state at the inlet condition of the compressor that circulates the fluid. To perform the pressure increase, a new cryogenic pump has been designed. To evaluate the new equipment, measurements were taken on liquid ethane over the temperature range 146–256 K at pressure between 0.9 and 5.1 MPa.     

Ice formation process by cooling water–oil emulsion with stirring in a vessel

An emulsion, which was a mixture of silanol-aqueous solution and silicone oil, was investigated as a heat storage material for a dynamic type ice storage system. The emulsion was poured into a vessel, which was immersed into a constant temperature bath at a low temperature, and frozen with stirring. Using stainless steel vessels coated with PFA resin and PTFE vessels with different thickness, the experiments were carried out under various conditions of temperature. Measuring the temperature history in the vessel, overall heat transfer coefficients before the start of freezing and during the ice formation were obtained. The effects of the material of the cooling surface and the thermal resistance of the wall on the ice formation process were clarified. If the heat flux of the wall was less than a critical value, slurry ice was formed without adhesion to the cooling surface. The results obtained under the same condition of the thermal resistance proved that it was effective against ice adhesion to coat PFA resin inside the vessel. It was found by the experiments in which the PTFE vessels were used that the critical value of the heat flux was nearly constant regardless of the thermal resistance.     

Effect of deflecting ring on noise generated by outdoor set of a split-unit air conditioner

In order to analyze the influence of the deflecting ring on the noise generated by the outdoor set of a split-unit air conditioner, the flow field in the outdoor set is simulated with the CFD software STAR-CD, the relative turbulent intensities are computed and the influence of the width and contoured duct of the deflecting ring on the noise generated by the outdoor set is analyzed. The results of computation and experiment show that there is an optimal width of the deflecting ring, corresponding to the minimum noise generated by the outdoor set. In addition, the influence of the contoured duct of the deflecting ring on the noise generated by the outdoor set is analyzed and a double contoured duct is designed. The results of computation and experiment verify that the deflecting ring with double contoured duct can improve the aerodynamic performance and reduce the noise generated by the outdoor set.     

Tribologische Kennwerte für Reibwerkstoffe

Tribology parameters for friction materials The tribology parameters of the friction materials are currently the coefficient of friction and the wear coefficient. They are determined depending on the material, the surface pressure and the frictional speed. These two parameters are not sufficient for an evaluation of the friction materials on the basis of a wear theory. Their validity is therefore limited. It is proposed to evaluate the friction materials on the basis of the energetic wear theory. The parameters are then the wear energy density, the shear stress of friction and the linear wear intensity. These values can be shown in a diagram and allow for the direct comparison of widely varying friction materials. The reference coefficient of friction is being introduced as a new wear parameter. The determination of the proposed parameters is made on a flywheel test rig, combined with the laser‐optical online measurement of the wear particles. It was possible to demonstrate that the parameters correctly describe the practice‐relevant requirements using two proven friction materials.     

Parametric optimization of a new combined refrigeration cycle – active thermal potentiostatting system

The active thermal potentiostatting system proposed by Martinovskii and Tsirlin is directly generalized to a more practical case, in which one intermediate chamber, besides a thermal potentiostatting chamber, and two irreversible refrigeration cycles are included and the influence of the thermal resistance between the working fluid and the reservoirs, the heat leakages from the environment to the intermediate chamber and from the intermediate chamber to the potentiostatting chamber are taken into account. Expressions for the main parameters of the system are derived. By using the optimal control theory, the minimum total power input of the system with non-zero cooling rates is calculated and the temperatures of the working fluid in the isothermal processes of the refrigeration cycles are optimized. The optimal allocation of the heat-transfer areas of the heat-exchangers in the refrigeration cycles is discussed in detail. The results obtained here are more general and useful than the relevant results in literature and can provide some valuable guidance for the optimal design and operation of real active thermal potentiostatting systems.     

Verbesserung des Eigenspannungszustands beim Kaltfließpressen durch den aktiven Einsatz eines gesteuerten Gegenstempels

By using an active counter punch during cold extrusion, the residual stress of the component can significantly be improved, which can increase its fatigue strength. In general, the workpieces produced through full‐forward extrusion are characterized by a strongly unfavourable stress state: The resulting high axial tensile residual stresses on the surface as well as the steep stress gradient accelerate the formation and the growth of cracks during cyclic loading. A system developed by the authors, consisting of a counter punch actively employed during the forming process allows improving the residual stress state of the final product. This result is obtained through a homogenization of the deformations in the samples during the cold extrusion. Therefore, a finite element simulation of the process was developed in Simufact Forming®. The simulation was experimentally validated by using the two austenitic steels 1.4307 and 1.4404. Another focus is the development of suitable measuring strategies for the X‐ray residual stress analysis with the sin²Ψ‐method to ensure the quality of the measurement results despite coarse‐grained and anisotropic microstructures. The results of the simulations and the experiments show that his technique has a considerable potential to increase the product quality without modifying the process time.     

An experimental study on minimizing frost deposition on a cold surface under natural convection conditions by use of a novel anti-frosting paint. Part II. Long-term performance, frost layer observation and mechanism analysis

In this part of study, the comparative observations of the structure and the surface temperature of the frost layer of both the coated and uncoated surfaces ware carried out and a preliminary analysis was presented. A series of the repeated cycling tests were completed that lasted for more than 2 months, and the influences of the coating thickness were also investigated. The results show that the frost layer deposited on the coating surface has a very fragile structure and can be removed easily by external force. The coating thickness has an important effect on the anti-frosting performance of the paint. The results also show that the coating of the paint on the copper surface is durable and presents a very good repeated cycling performance.     

The Influence of Nitrogen and Boron Implant into Silicon Substrate on the Phase and Internal Stress of c-BN Films

Cubic boron nitride(c-BN) film was deposited on a Si (100) substrate by the RF-magnetron sputtering.The mainly problems for fabrication of c-BN films are the low purity and high intrinsic compressive stress. In order to solve the two problems, the c-BN film with the buffer interlayer was deposited on the substrate which had been implanted with nitrogen and/or boron ions. The results show: the implantation of nitrogen ions can obviously increase c-BN content and reduce the internal stress slightly; while the implantation of boron shows no obvious improvement to the content of c-BN, which can reduce the internal stress in the film obviously. In addition, it is suggested that the implantation of nitrogen and boron shows the best result, which not only can increase the content of c-BN, but also reduce the internal stress in the c-BN film obviously.     

Two-phase split of refrigerants at a T-junction

The present study experimentally investigated the two-phase flow split of refrigerants at a T-junction. As geometric parameters, the direction of the inlet or branch tube and the tube diameter ratio of branch to inlet tube were chosen. As inlet flow parameters, the inlet mass flux and quality were varied from 100 to 700 kg m⁻² s⁻¹ and from 0.1 to 0.9, respectively, for the condition of distribution header of a multi-pass evaporator in the general refrigeration system. All experiments were performed for R-22, R-134a, and R-410A. The measured data were compared with the values predicted by the models developed for air–water or steam–water mixture in the literature. We propose a modified model for application to the reduced T-junction and vertical orientation of tubes. Among the geometric parameters, the branch tube direction showed the largest sensitivity to the mass flow rate ratio for the gas phase, while the inlet quality showed the largest sensitivity to the mass flow rate ratio among the inlet flow parameters.     

Corrosion Resistance of an electrodeposited Zinc Coating Containing CeO2 Nanoparticles

A Zinc coating containing CeO2 nanoparticles has been deposited by electrodeposition in a zinc plating bath.The content of CeO2 in the coating is 0.22 mass%. The results of weight loss experiments and electrochemistry tests show that corrosion resistance of the Zinc coating containing CeO2 nanoparticles is remarkably improved in contrast to the pure zinc coating in 0.5 M MgSO4 solution. The effects of CeO2 microparticles on the corrosion resistance of the zinc coating have been studied, the results show that CeO2 microparticles have no effect on the corrosion resistance of the zinc coating. SEM and XRD experiments suggest that the presence of CeO2 nanoparticles in the coating causes the modification of the surface morphology and preferential orientation of the crystal planes; therefore, the reason for the enhancement of corrosion resistance is mainly related to improvement of the structure of the coating.     

Numerical Analysis of Powder Properties in Low Power Plasma Torch

A mathematical model was presented to describe the particle trajectory, velocity and temperature properties in the low power plasma spraying torch (3.6 kW)in which powder particles were directly injected into the region between the cathode and anode. The results show that the characteristics of the particles by low power plasma spraying are similar to that by traditional APS( Atmosphere plasma spraying) in 40 kW. The velocities of the particles increase with the increase of inlet gas flow rate, current and percentage of nitrogen and hydrogen, while the temperature of the powder increase with the decrease of the gas flow rate and with the increase of current and percentage of nitrogen and hydrogen.     

Modeling of a domestic frost-free refrigerator

In the present study, a comprehensive thermo-fluidic model is developed for a domestic frost-free refrigerator. The governing equations, coupled with pertinent boundary conditions, are solved by employing a conservative control volume formulation, in the environment of a three-dimensional unstructured mesh. Experiments are also conducted to validate the results predicted by the present computational model. It is found that the computational and experimental results qualitatively agree with each other, although certain discrepancies can be observed in terms of the exact numerical values obtained. For the freezer compartment, the computationally predicted temperatures are somewhat higher than the experimental ones, whereas for the refrigerating compartment, the computed temperatures are lower than the corresponding experimental observations. The difference between experimental and computational results may be attributed to the lack of precise data on the airflow rates and the unaccounted heat transfer rates through the door gaskets and the compressor. From the heat transfer and fluid flow analysis, certain modifications in the design are also suggested, so as to improve the performance of the refrigerator.     

Unified damage description and risk assessment of buildings under extreme natural hazards

Internationally different classification schemes are available for the assessment of structural damage due to the different natural hazards. Due to their heterogeneity, these classification schemes are insufficiently suited for the consideration of damage in the sense of a multi hazard approach. A unified system is necessary for the evaluation of the building vulnerability and the damage prognosis due the different natural hazards. The unified system transfers repeatedly observed damage patterns into a scheme of damage grades. With this instrument, the structural damage can be uniformly evaluated and the relationship to the input parameters can be established. Following the concept of the European Macroseismic Scale 1998 (EMS‐98) for earthquake damage, it is distinguished between structural and non‐structural damage to which characteristic damage patterns can be assigned in the form of damage grades. A general classification scheme for building damage is presented, which enables a comparison of the damage due to the individual natural hazards. On the basis of real observed damage cases, the typical damage patterns for the natural hazards flood, tsunami and wind are highlighted and converted into harmonized classification schemes for damage grades. For the first time, a harmonized set of instruments is available for evaluation of damage cases on a building stock as a result of different natural hazards according to criteria standardized in engineering terms. The outlook refers to the damage prognosis due to the different natural hazards and their possible sequences.     

Capturing Nitrosamines in Environment by Zeolite

To meet the requirement of environment protection, the adsorption of volatile nitrosamines, which are carcinogenic compounds in tobacco smoke, by zeolite is investigated in this article, along with the temperature programmed surface reaction of nitrosamines on zeolite to assess the catalytic capability of the porous material on the decomposition of the carcinogens. The actual function of zeolite to reduce the level of nitrosamines in cigarette smoke is also studied. The influences of zeolite pore's structure and the surface acid-basic properties of the adsorbent on the adsorption are explored in terms of geometric matching content and adsorbent-adsorbate interaction. Moreover, the role played by the cation of zeolite in the adsorption of volatile nitrosamines is discussed and the possible attracting range of the sodium cation in basic zeolite to pull the nitrosamine molecule is tentatively calculated. Owing to the specific ability of capturing nitrosamines, zeolite is proven to be the most effective additive encased within a cigarette as the functional additive for lowering the nitrosamines content of smoke to protect the environment and public health. Other porous oxides such as amorphous silica and alumina are also utilized in these experiments, and their actual functions to trap nitrosamines as well as their potential application as the candidates for cigarette additives are discussed and prospected, too.     

Wall and fluid inlet temperature effect on heat transfer in incompressible laminar oscillating flows

This paper deals with the problem of oscillating flows occurring in devices such as Stirling or thermoacoustic engines and refrigerators. Since the global governing equations cannot be solved, the authors propose to introduce a few simplifications; the most simplifying reduction is that the fluid is assumed to be incompressible. However, specific attention is paid to describing the flow characteristics that's why the Lagrangian formalism which allows the individual study of each fluid particle is adopted. Thereby each particle contribution to global thermal effects can be evaluated and the gas temperature profiles along the exchanger can be computed. Various situations are presented including the case of a non-uniform temperature at the wall and a phase lag between pressure and temperature at the fluid entrance. The efficiency of the wall to fluid thermal exchange is analyzed. The authors show that this exchange depends upon two important parameters: the geometric ratio between the exchanger length and the particle oscillating displacement, and a thermal parameter “β”, governing the temperature profiles and related to the Prandtl number, the operating frequency and the phase lag between the instantaneous heat flux and the wall to fluid temperature difference.     

Ausgewählte Ergebnisse der Untersuchung der Prozesse des Schmelzens und der Erstarrung beim Schmelzschweißen und Schmelzlöten mittels der materiellen Modellierung

In the article a method for the material modelling is described under application of visually transparent materials of the thermal and chemical solidification processes when welding and soldering. All solidification processes carried out independently of the form of the primary crystals, first about the planar one, then cellular and in the end dendritically growth the solidification structure. It is determined by the chemical composition of the weld and soldering good, the weld, soldering, crystallization or solidification speeds and by the temperature gradients at the solidification front particularly. The vacancy concentration is made by the temporary formation of so‐called zipper primary grain boundaries in the solidification structure when welding. Among other things a preferential growth direction of the primary crystals explains itself by the fast growth of so‐called victim crystals which completes the known theories of the preferential growth.     

Intelligence and impact contests in systems with redundancy, false targets, and partial protection

The paper considers a system consisting of identical elements that can be intentionally attacked. The cumulative performance of the system elements should meet a demand. To prevent loss of demand the defender provides system redundancy (deploying genuine system elements (GEs) with cumulative performance exceeding the demand); deploys false elements (FEs), and protects the GEs. If the attacker cannot distinguish GEs and FEs, he chooses the number of elements to attack and attacks at random these elements distributing his resource evenly among the attacked elements. In order to get the information about the system the attacker allocates a part of his resource into the intelligence activity. Analogously, the defender allocates a part of his resource into the counter-intelligence activity. The attacker's strategy presumes distribution of his resource among the intelligence and attack effort and choice of the number of attacked elements. If the attacker wins the intelligence contest, he can identify both FEs and unprotected GEs ignoring the former ones and destroying the latter ones with negligible effort. The defender's strategy presumes distribution of his resource among the counter-intelligence and the three defensive actions. The paper considers a three-period non-cooperative minmax game between the defender and the attacker and presents an algorithm for determining the agents’ optimal strategies.     

Today's sheet metal materials and their forming properties

The production and processing of sheet metals of high‐strength steels, titanium, aluminum or magnesium alloys is investigated intensively at universities and in the industry. The main emphasis is put for example on the aluminum space frame concept as well as on the succeeding projects of the ULSAB‐study in the field of the steel sheet metals. Within this article the qualification of the above mentioned materials for the application as deep‐drawing materials will be discussed. The aim of the development for new deep‐drawing sheet metals is to decrease the elastic part of the forming, which means to lower the yield point. A high elastic portion would cause a high resilience after the forming of the sheet metals and therefore an increased requirement of force and form error during the forming process. Furthermore the optimized sheet metal material should have a great uniform elongation, so that it can be plastically deformed in a wide range. The beginning of the deformation should be possible at low forming forces but due to the deformation an increase of the hardening should be caused, so that the finished component has high strength. But it is not possible to realize both aims, high strength and great uniform elongation, at the same time.