Global efficiency of innovative rotational mold directly heated by thermal fluid

The article is focused on analysis of global efficiency of new mold for rotational molding of plastic parts, being directly heated by thermal fluid. The overall efficiency is based on several items such as reduction of cycle time, better uniformity of heating-cooling and low energy consumption. The new tool takes advantage of additive fabrication and electroforming for making the optimal manifold and cavity shell of the mold. Experimental test of a prototype mold was carried out on an experimental rotational molding machine, developed for this purpose, measuring wall temperature, and internal air temperature, with and without plastic material inside. Results were compared with conventional mold heated into an oven and to theoretical simulations done by Computational Fluid Dynamic software (CFD). The analysis represents considerable improvement of cycle time related to conventional methods (heated by oven) and better thermal uniformity to conventional procedures by direct heating of oil with external channels. In addition to thermal analysis an energetic efficiency study was done. POLYM. ENG. SCI., 52:1998-2005, 2012. © 2012 Society of Plastics Engineers Copyright © 2012 Society of Plastics Engineers.

Development and Validation of a Compact Thermal Model for an Aircraft Compartment

The development of accurate structural/thermal numerical models of complex systems, such as aircraft fuselage barrels, is often limited and determined by the smallest scales that need to be modelled. The development of reduced order models of the smallest scales and consequently their integration with higher level models can be a way to minimise the bottle neck present, while still having efficient, robust and accurate numerical models. In this paper a methodology on how to develop compact thermal fluid models (CTFMs) for compartments where mixed convection regimes are present is demonstrated. Detailed numerical simulations (CFD) have been developed for an aircraft crown compartment and validated against experimental data obtained from a 1:1 scale compartment rig. The crown compartment is defined as the confined area between the upper fuselage and the passenger cabin in a single aisle commercial aircraft. CFD results were utilised to extract average quantities (temperature and heat fluxes) and characteristic parameters (heat transfer coefficients) to generate CTFMs. The CTFMs have then been compared with the results obtained from the detailed models showing average errors for temperature predictions lower than 5%. This error can be deemed acceptable when compared to the nominal experimental error associated with the thermocouple measurements.

The CTFMs methodology developed allows to generate accurate reduced order models where accuracy is restricted to the region of Boundary Conditions applied. This limitation arises from the sensitivity of the internal flow structures to the applied boundary condition set. CTFMs thus generated can be then integrated in complex numerical modelling of whole fuselage sections.

Further steps in the development of an exhaustive methodology would be the implementation of a logic ruled based approach to extract directly from the CFD simulations numbers and positions of the nodes for the CTFM.

Single-phase fluid flow distribution and heat transfer in microstructured reactors

Single-phase microreactors and micro-heat-exchangers have been widely used in industrial and scientific applications over the last decade. In several cases, operation of microreactors has shown that their expected efficiency cannot be reached either due to non-uniform distribution of reactants between different channels or due to flow maldistribution between individual microreactors working in parallel. The latter problem can result in substantial temperature deviations between different microreactors resulting in thermal run away which could arise from an exothermicreaction. Thus advances in the understanding of heat transfer and fluid flow distribution continue to be crucial in achieving improved performance, efficiency and safety in microstructured reactors used for different applications. This paper presents a review of the experimental and numerical results on fluid flow distribution, heat transfer and combination thereof, available in the open literature. Heat transfer in microchannels can be suitably described by standard theory and correlations, but scaling effects (entrance effects, conjugate heat transfer, viscous heating, and temperature-dependent properties) have often to be accounted for in microsystems. Experiments with single channels are in good agreement with predictions from the published correlations. The accuracy of multichannel experiments is lower due to flow maldistribution. Special attention is devoted to theoretical and experimental studies on the effect of a flow maldistribution on the thermal and conversion response of catalytic microreactors. There view concludes with a set of design recommendations aimed at improving the reactor performance. (C) 2010 Elsevier Ltd. All rights reserved.

Dynamical characteristics of solitary waves, shocks and envelope modes in kappa-distributed non-thermal plasmas: an overview

Space plasmas provide abundant evidence of highly energetic particle population, resulting in a long-tailed non-Maxwellian distribution. Furthermore, the first stages in the evolution of plasmas produced during laser-matter interaction are dominated by nonthermal electrons, as confirmed by experimental observation and computer simulations. This phenomenon is efficiently modelled via a kappa-type distribution. We present an overview, from first principles, of the effect of superthermality on the characteristics of electrostatic plasma waves. We rely on a fluid model for ion-acoustic excitations, employing a kappa distribution function to model excess superthermality of the electron distribution. Focusing on nonlinear excitations (solitons), in the form of solitary waves (pulses), shocks and envelope solitons, and employing standard methodological tools of nonlinear plasmadynamical analysis, we discuss the role of excess superthermality in their propagation dynamics (existence laws, stability profile), geometric characteristics and stability. Numerical simulations are employed to confirm theoretical predictions, namely in terms of the stability of electrostatic pulses, as well as the modulational stability profile of bright- and dark-type envelope solitons.

Multiphysics Simulation of Thermal Plasma Produced by Lightning Strike on Aircraft Structures

A novel numerical technique is proposed to model thermal plasma of microseconds/milliseconds time-scale effect. Modelling thermal plasma due to lightning strike will allow the estimation of electric current density, plasma pressure, and heat flux at the surface of the aircraft structure. These input data can then be used for better estimation of the mechanical/thermal induced damage on the aircraft structures for better protection systems design. Thermal plasma generated during laser cutting, electric (laser) welding and other plasma processing techniques have been the focus of many researchers. Thermal plasma is a gaseous state that consists from a mixture of electrons, ions, and natural particles. Thermal plasma can be assumed to be in local thermodynamic equilibrium, which means the electrons and the heavy species have equal temperature. Different numerical techniques have been developed using a coupled Navier Stokes – Heat transfer – Electromagnetic equations based on the assumption that the thermal plasma is a single laminar gas flow. These previous efforts focused on generating thermal plasma of time-scale in the range of seconds. Lighting strike on aircraft structures generates thermal plasma of time-scale of milliseconds/microseconds, which makes the previous physics used not applicable. The difficulty comes from the Navier-Stokes equations as the fluid is simulated under shock load, this introducing significant changes in the density and temperature of the fluid.

Calibrated CFD simulation to evaluate thermal comfort in a highly-glazed naturally ventilated room

Natural ventilation is a sustainable solution to maintaining healthy and comfortable environmental conditions in buildings. However, the effective design, construction and operation of naturally ventilated buildings require a good understanding of complex airflow patterns caused by the buoyancy and wind effects.The work presented in this article employed a 3D computational fluid dynamics (CFD) analysis in order to investigate environmental conditions and thermal comfort of the occupants of a highly-glazed naturally ventilated meeting room. This analysis was facilitated by the real-time field measurements performed in an operating building, and previously developed formal calibration methodology for reliable CFD models of indoor environments. Since, creating an accurate CFD model of an occupied space in a real-life scenario requires a high level of CFD expertise, trusted experimental data and an ability to interpret model input parameters; the calibration methodology guided towards a robust and reliable CFD model of the indoor environment. This calibrated CFD model was then used to investigate indoor environmental conditions and to evaluate thermal comfort indices for the occupants of the room. Thermal comfort expresses occupants' satisfaction with thermal environment in buildings by defining the range of indoor thermal environmental conditions acceptable to a majority of occupants. In this study, the thermal comfort analysis, supported by both field measurements and CFD simulation results, confirmed a satisfactory and optimal room operation in terms of thermal environment for the investigated real-life scenario. © 2013 Elsevier Ltd.

Assessment of the double-skin façade passive thermal buffer effect.

Double Skin Façades (DSFs) are becoming increasingly popular architecture for commercial office buildings. Although DSFs are widely accepted to have the capacity to offer significant passive benefits and enable low energy building performance, there remains a paucity of knowledge with regard to their operation. Identification of the most determinant architectural parameters of DSFs is the focus of ongoing research. This paper presents an experimental and simulation study of a DSF installed on a commercial building in Dublin, Ireland. The DSF is south facing and acts to buffer the building from winter heat losses, but risks enhancing over-heating on sunny days. The façade is extensively monitored during winter months. Computational Fluid Dynamic (CFD) models are used to simulate the convective operation of the DSF. This research concludes DSFs as suited for passive, low energy architecture in temperature climates such as Ireland but identifies issues requiring attention in DSF design.

Data-Driven Dynamic Modeling of Coupled Thermal and Electric Outputs of Microturbines

Microturbines are among the most successfully commercialized distributed energy resources, especially when they are used for combined heat and power generation. However, the interrelated thermal and electrical system dynamic behaviors have not been fully investigated. This is technically challenging due to the complex thermo-fluid-mechanical energy conversion processes which introduce multiple time-scale dynamics and strong nonlinearity into the analysis. To tackle this problem, this paper proposes a simplified model which can predict the coupled thermal and electric output dynamics of microturbines. Considering the time-scale difference of various dynamic processes occuring within microturbines, the electromechanical subsystem is treated as a fast quasi-linear process while the thermo-mechanical subsystem is treated as a slow process with high nonlinearity. A three-stage subspace identification method is utilized to capture the dominant dynamics and predict the electric power output. For the thermo-mechanical process, a radial basis function model trained by the particle swarm optimization method is employed to handle the strong nonlinear characteristics. Experimental tests on a Capstone C30 microturbine show that the proposed modeling method can well capture the system dynamics and produce a good prediction of the coupled thermal and electric outputs in various operating modes.

Constant wall heat flux boundary conditions in micro-channels filled with porous material with internal heat generation under local thermal non-equilibrium conditions

Forced convection heat transfer in a micro-channel filled with a porous material saturated with rarefied gas with internal heat generation is studied analytically in this work. The study is performed by analysing the boundary conditions for constant wall heat flux under local thermal non-equilibrium (LTNE) conditions. Invoking the velocity slip and temperature jump, the thermal behaviour of the porous-fluid system is studied by considering thermally and hydrodynamically fully-developed conditions. The flow inside the porous material is modelled by the Darcy–Brinkman equation. Exact solutions are obtained for both the fluid and solid temperature distributions for two primary approaches models A and B using constant wall heat flux boundary conditions. The temperature distributions and Nusselt numbers for models A and B are compared, and the limiting cases resulting in the convergence or divergence of the two models are also discussed. The effects of pertinent parameters such as fluid to solid effective thermal conductivity ratio, Biot number, Darcy number, velocity slip and temperature jump coefficients, and fluid and solid internal heat generations are also discussed. The results indicate that the Nusselt number decreases with the increase of thermal conductivity ratio for both models. This contrasts results from previous studies which for model A reported that the Nusselt number increases with the increase of thermal conductivity ratio. The Biot number and thermal conductivity ratio are found to have substantial effects on the role of temperature jump coefficient in controlling the Nusselt number for models A and B. The Nusselt numbers calculated using model A change drastically with the variation of solid internal heat generation. In contrast, the Nusselt numbers obtained for model B show a weak dependency on the variation of internal heat generation. The velocity slip coefficient has no noticeable effect on the Nusselt numbers for both models. The difference between the Nusselt numbers calculated using the two models decreases with an increase of the temperature jump coefficient.

Temperature fields in a channel partially filled with a porous material under local thermal non-equilibrium condition-an exact solution

This work examines analytically the forced convection in a channel partially filled with a porous material and subjected to constant wall heat flux. The Darcy–Brinkman–Forchheimer model is used to represent the fluid transport through the porous material. The local thermal non-equilibrium, two-equation model is further employed as the solid and fluid heat transport equations. Two fundamental models (models A and B) represent the thermal boundary conditions at the interface between the porous medium and the clear region. The governing equations of the problem are manipulated, and for each interface model, exact solutions, for the solid and fluid temperature fields, are developed. These solutions incorporate the porous material thickness, Biot number, fluid to solid thermal conductivity ratio and Darcy number as parameters. The results can be readily used to validate numerical simulations. They are, further, applicable to the analysis of enhanced heat transfer, using porous materials, in heat exchangers.