An integrated model of rolling tyre vibrations on a smooth road

We describe new results on the vibrations of rolling tyres, aimed at noise prediction for tyres of given design on a smooth road surface. This new approach incorporates our existing models, of smooth road-tyre interaction and belt vibration but includes additional features that are required for real tyre patterns. To this end, the model allows variable tread block size and grooves along the belt circumference; the density and angle of these grooves may also vary laterally. The key innovation is to treat the tyre belt as a laterally stacked series of rings, each of which is equipped with a set of viscoelastic springs around its circumference. It is shown how to use this construction to mimic the details of actual tyre patterns and, in conjunction with existing models, predict belt vibrations. The construction is applied to develop a ring discretisation for a real tyre that shows strong lateral variations. It is shown that the vibration amplitude is concentrated on a set of parallel lines in frequency-wavenumber space and that the tread pattern dictates the occurrence and spacing of these lines. Linkage to a boundary element calculation then allows quantification of the influence of tread parameters on radiated noise. Keywords: Vibration, tread pattern, tyre noise. Copyright © (2011) by the Institute of Noise Control Engineering.

Large eddy simulation of a hot, high speed coflowing jet

Computations are made of a short cowl coflowing jet nozzle with a bypass ratio 8 : 1. The core flow is heated, making the inlet conditions reminiscent of those for a real engine. A large eddy resolving approach is used with a 12 × 106 cell mesh. Since the code being used tends towards being dissipative the sub-grid scale (SGS) model is abandoned giving what can be termed Numerical Large Eddy Simulation (NLES). To overcome near wall modelling problems a hybrid NLES-RANS (Reynolds Averaged Navier-Stokes) related method is used. For y+ ≤ 60 a κ-l model is used. Blending between the two regions makes use of the differential Hamilton-Jabobi (HJ) equation, an extension of the eikonal equation. Results show encouraging agreement with existing measurements of other workers. The eikonal equation is also used for acoustic ray tracing to explore the effect of the mean flow on acoustic ray trajectories, thus yielding a coherent solution strategy. Copyright © 2011 by ASME.

Use of axially graded burnable boron for hot-spot temperature reduction in a pressurized water reactor core

Shortly after the loading of a pressurized water reactor (PWR) core, the axial power distribution in fresh fuel has already attained the characteristic, almost flat shape, typical of burned fuel. At beginning of cycle (BOC), however, the axial distribution is centrally peaked. In assemblies hosting uniform burnable boron rods, this BOC peaking is even more pronounced. A reduction in the axial peaking is today often achieved by shortening the burnable boron rods by some 30 cm at each edge. It is shown that a two-zone grading of the boron rod leads, in a representative PWR cycle, to a reduction of the hot-spot temperature of approximately 70 °C, compared with the nongraded case. However, with a proper three-zone grading of the boron rod, an additional 20 °C may be cut off the hot-spot temperature. Further, with a slightly skewed application of this three-zone grading, an additional 50 °C may be cut off. The representative PWR cycle studied was cycle 11 of the Indian Point 2 station, with a simplification in the number of fuel types and in the burnup distribution. The analysis was based on a complete three-dimensional burnup calculation. The code system was ELCOS, with BOXER as an assembly code for the generation of burnup-dependent cross sections and SILWER as a three-dimensional core code with thermal-hydraulic feedback.

Manufacturing dish shaped rings on radial-axial ring rolling mills

Ring rolling is an established method to produce seamless rings of different cross-sectional geometries. For dish shaped rings, there are applications in different areas such as offshore, aeronautics or the energy sector. At the moment, dish shaped rings are produced by machining of rings with rectangular shaped cross section, by (open die) hollow forging on a conical mandrel or by using shaped ring rolling tools. These ways of manufacturing have the disadvantage of high material waste, additional costs for special tools, long process time and limited or inflexible geometries. Therefore, the manufacturing of dish shaped rings on conventional radial-axial ring rolling mills would expand the range of products for ring producers. The aim of this study is to investigate the feasibility of an alternative to the current manufacturing processes, without requiring additional tooling and material costs. Therefore, the intended formation of dish shaped rings-previously regarded as a form error-is investigated. Based on an analysis of geometrical requirements and metal flow mechanisms, a rolling strategy is presented, causing dishing and ring climbing by a large height reduction of the ring. Using this rolling strategy dish shaped rings with dishing angles up to 18° were achieved. In addition to the experiments finite element method (FEM)-simulations of the process have been successfully conducted, in order to analyze the local strain evolution. However, when the contact between ring and main roll is lost in the process the ring starts to oscillate around the mandrel and neither dishing nor ring climbing is observed. © 2013 German Academic Society for Production Engineering (WGP).

Numerical simulations supporting the process design of ring rolling processes

In conventional Finite Element Analysis (FEA) of radial-axial ring rolling (RAR) the motions of all tools are usually defined prior to simulation in the preprocessing step. However, the real process holds up to 8 degrees of freedom (DOF) that are controlled by industrial control systems according to actual sensor values and preselected control strategies. Since the histories of the motions are unknown before the experiment and are dependent on sensor data, the conventional FEA cannot represent the process before experiment. In order to enable the usage of FEA in the process design stage, this approach integrates the industrially applied control algorithms of the real process including all relevant sensors and actuators into the FE model of ring rolling. Additionally, the process design of a novel process 'the axial profiling', in which a profiled roll is used for rolling axially profiled rings, is supported by FEA. Using this approach suitable control strategies can be tested in virtual environment before processing. © 2013 AIP Publishing LLC.

Finite element analysis of the ring rolling process with integrated closed-loop control

In FEA of ring rolling processes the tools' motions usually are defined prior to simulation. This procedure neglects the closed-loop control, which is used in industrial processes to control up to eight degrees of freedom (rotations, feed rates, guide rolls) in real time, taking into account the machine's performance limits as well as the process evolution. In order to close this gap in the new simulation approach all motions of the tools are controlled according to sensor values which are calculated within the FE simulation. This procedure leads to more realistic simulation results in comparison to the machine behaviour. © 2012 CIRP.

Effect of process parameters on the morphology and nanostructure of roll-to-roll printed P3HT:PCBM thin films for organic photovoltaics

Roll-to-roll (R2R) gravure exhibits significant advantages such as high precision and throughput for the printing of photoactive and conductive materials and the fabrication of flexible organic electronics such as organic photovoltaics (OPVs). Since the photoactive layer is the core of the OPV, it is important to investigate and finally control the process parameters and mechanisms that define the film morphology in a R2R process. The scope of this work is to study the effect of the R2R gravure printing and drying process on the nanomorphology and nanostructure of the photoactive P3HT:PCBM thin films printed on PEDOT:PSS electrodes towards the fabrication of indium tin oxide (ITO)-free flexible OPVs. In order to achieve this, P3HT:PCBM blends of different concentration were R2R printed under various speeds on the PEDOT:PSS layers. Due to the limited drying time during the rolling, an amount of solvent remains in the P3HT:PCBM films and the slow-drying process takes place which leads to the vertical and lateral phase separation, according to the Spectroscopic Ellipsometry and Atomic Force Microscopy analysis. The enhanced slow-drying leads to stronger phase separation, larger P3HT crystallites according to the Grazing Incidence X-Ray Diffraction data and to weaker mechanical response as it was shown by the nanoindentation creep. However, in the surface of the films the P3HT crystallization is controlled by the impinged hot air during the drying, where the more the drying time the larger the surface P3HT crystallites. The integration of the printed P3HT:PCBM and PEDOT:PSS layers in an OPV device underlined the feasibility of fabricating ITO-free flexible OPVs by R2R gravure processes. © 2013 Elsevier B.V.

Efficient strategies for process design and optimization in ring rolling

Ring rolling is an incremental bulk forming process for the near-net-shape production of seamless rings. This paper shows how nowadays the process design and optimization can be efficiently supported by simulation methods. For reliable predictions of the material flow and the microstructure evolution it's necessary to include a real ring rolling mill's control algorithm into the model. Furthermore an approach for the online measurement of the profile evolution during the process is presented by means of axial profiling in ring rolling. Hence the definition of new ring rolling strategies is possible even for advanced geometries.

Simulations of autoignition and laminar premixed flames in methane/air mixtures diluted with hot products

This article considers constant-pressure autoignition and freely propagating premixed flames of cold methane/air mixtures mixed with equilibrium hot products at high enough dilution levels to burn within the moderate to intense low oxygen dilution (MILD) combustion regime. The analysis is meant to provide further insight on MILD regime boundaries and to identify the effect of hot products speciation. As the mass fraction of hot products in the reactants mixture increases, autoignition occurs earlier. Species profiles show that the products/reactants mixture approximately equilibrates to a new state over a quick transient well before the main autoignition event, but as dilution becomes very high, this equilibration transient becomes more prominent and eventually merges with the primary ignition event. The dilution level at which these two reactive zones merge corresponds well with that marking the transition into the MILD regime, as defined according to conventional criteria. Similarly, premixed flame simulations at high dilutions show evidence of significant reactions involving intermediate species prior to the flame front. Since the premixed flame governing equations system demands that the species and temperature gradients be zero at the "cold" boundary, flame speed cannot be calculated above a certain dilution level. Up to this point, which again agrees reasonably well with the transition into the MILD regime according to convention, the laminar burning velocity was found to increase with hot product dilution while flame thickness remained largely unchanged. Some comments on the MILD combustion regime boundary definition for gas turbine applications are included. Copyright © Taylor & Francis Group, LLC.

Design and control of a climbing robot based on hot melt adhesion

Robust climbing in unstructured environments has been one of the long-standing challenges in robotics research. Among others, the control of large adhesion forces is still an important problem that significantly restricts the locomotion performance of climbing robots. The main contribution of this paper is to propose a novel approach to autonomous robot climbing which makes use of hot melt adhesion (HMA). The HMA material is known as an economical solution to achieve large adhesion forces, which can be varied by controlling the material temperature. For locomotion on both inclined and vertical walls, this paper investigates the basic characteristics of HMA material, and proposes a design and control of a climbing robot that uses the HMA material for attaching and detaching its body to the environment. The robot is equipped with servomotors and thermal control units to actively vary the temperature of the material, and the coordination of these components enables the robot to walk against the gravitational forces even with a relatively large body weight. A real-world platform is used to demonstrate locomotion on a vertical wall, and the experimental result shows the feasibility and overall performances of this approach. © 2013 Elsevier B.V. All rights reserved.