Control of transient thermal response during sequential open-die forging: A trajectory optimization approach

A trajectory optimization approach is applied to the design of a sequence of open-die forging operations in order to control the transient thermal response of a large titanium alloy billet. The amount of time tire billet is soaked in furnace prior to each successive forging operation is optimized to minimize the total process time while simultaneously satisfying constraints on the maximum and minimum values of the billet's temperature distribution to avoid microstructural defects during forging. The results indicate that a "differential" heating profile is the most effective at meeting these design goals.

Computer-Based Design Synthesis Research: An Overview

One of the hallmarks of engineering design is the design synthesis phase where the creativity of the designer most prominently comes into play as solutions are generated to meet underlying needs. Over the past decades, methodologies for generating concepts and design solutions have matured to the point that computation-based synthesis provides a means to explore a wider variety of solutions and take over more tedious design tasks. This paper reviews advances in function-based, grammar-based, and analogy-based synthesis approaches and their contributions to computational design synthesis research in the last decade. DOI: 10.1115/1.3593409]

Data rectification and detection of trend shifts in jet engine path measurements using median filters and fuzzy logic

Filtering methods are explored for removing noise from data while preserving sharp edges that many indicate a trend shift in gas turbine measurements. Linear filters are found to be have problems with removing noise while preserving features in the signal. The nonlinear hybrid median filter is found to accurately reproduce the root signal from noisy data. Simulated faulty data and fault-free gas path measurement data are passed through median filters and health residuals for the data set are created. The health residual is a scalar norm of the gas path measurement deltas and is used to partition the faulty engine from the healthy engine using fuzzy sets. The fuzzy detection system is developed and tested with noisy data and with filtered data. It is found from tests with simulated fault-free and faulty data that fuzzy trend shift detection based on filtered data is very accurate with no false alarms and negligible missed alarms.

A differential-geometric analysis of singularities of point trajectories of serial and parallel manipulators

In this paper, we present a differential-geometric approach to analyze the singularities of task space point trajectories of two and three-degree-of-freedom serial and parallel manipulators. At non-singular configurations, the first-order, local properties are characterized by metric coefficients, and, geometrically, by the shape and size of a velocity ellipse or an ellipsoid. At singular configurations, the determinant of the matrix of metric coefficients is zero and the velocity ellipsoid degenerates to an ellipse, a line or a point, and the area or the volume of the velocity ellipse or ellipsoid becomes zero. The degeneracies of the velocity ellipsoid or ellipse gives a simple geometric picture of the possible task space velocities at a singular configuration. To study the second-order properties at a singularity, we use the derivatives of the metric coefficients and the rate of change of area or volume. The derivatives are shown to be related to the possible task space accelerations at a singular configuration. In the case of parallel manipulators, singularities may lead to either loss or gain of one or more degrees-of-freedom. For loss of one or more degrees-of-freedom, ther possible velocities and accelerations are again obtained from a modified metric and derivatives of the metric coefficients. In the case of a gain of one or more degrees-of-freedom, the possible task space velocities can be pictured as growth to lines, ellipses, and ellipsoids. The theoretical results are illustrated with the help of a general spatial 2R manipulator and a three-degree-of-freedom RPSSPR-SPR parallel manipulator.

Wear of metals: a consequence of stable/unstable material response

Wear of metals in dry sliding is dictated by the material response to traction. This is demonstrated by considering the wear of aluminium and titanium alloys. In a regime of stable homogeneous deformation the material approaching the surface from the bulk passes through microprocessing zones of flow, fracture, comminution and compaction to generate a protective tribofilm that retains the interaction in the mild wear regime. If the response leads to microstructural instabilities such as adiabatic shear bands, the near-surface zone consists of stacks of 500 nm layers situated parallel to the sliding direction. Microcracks are generated below the surface to propagate normally away from the surface though microvoids situated in the layers, until it reaches a depth of 10-20 mum. A rectangular laminate debris consisting of a 20-40 layer stack is produced, The wear in this mode is severe.

Analytical solutions for heat transfer during cyclic melting and freezing of a phase change material used in electronic or electrical packaging

In this paper we develop an analytical heat transfer model, which is capable of analyzing cyclic melting and solidification processes of a phase change material used in the context of electronics cooling systems. The model is essentially based on conduction heat transfer, with treatments for convection and radiation embedded inside. The whole solution domain is first divided into two main sub-domains, namely, the melting sub-domain and the solidification sub-domain. Each sub-domain is then analyzed for a number of temporal regimes. Accordingly, analytical solutions for temperature distribution within each subdomain are formulated either using a semi-infinity consideration, or employing a method of quasi-steady state, depending on the applicability. The solution modules are subsequently united, leading to a closed-form solution for the entire problem. The analytical solutions are then compared with experimental and numerical solutions for a benchmark problem quoted in the literature, and excellent agreements can be observed.

A Note On The Effect Of Short And Long Laminar Separation-Bubbles On Desinent Cavitation

Earlier desinent cavitation studies on a 1/8 caliber ogive by one of the authors (J. W. H.) showed a sudden change in the magnitude of the desinent cavitation number at a critical velocity. In the present work it is shown by means of oil-film flow visualization that below the critical velocity a long laminar separation bubble exists whereas above the critical velocity the laminar separation bubble is short. Thus the desinent cavitation characteristics of a 1/8 caliber ogive are governed by the nature of the viscous flow around the body.

Inception of Cavitation From a Backward Facing Step

Cavitation inception measurements are reported for flow past a downstream facing step with the height of the step varying from about 0.4 to 5 percent of the forebody diameter. The forebody was a 49 mm hemispherical nose and sigmai values were found to be very strong function of the height of the step. In addition, sigmai values were found to depend on whether the boundary layer approaching the step was laminar or turbulent. Generally sigmai values for turbulent case were lower.

Thermal Weight Functions and Stress Intensity Factors for Bonded Dissimilar Media Using Body Analogy

In this study, an analytical method is presented for the computation of thermal weight functions in two dimensional bi-material elastic bodies containing a crack at the interface and subjected to thermal loads using body analogy method. The thermal weight functions are derived for two problems of infinite bonded dissimilar media, one with a semi-infinite crack and the other with a finite crack along the interface. The derived thermal weight functions are shown to reduce to the already known expressions of thermal weight functions available in the literature for the respective homogeneous elastic body. Using these thermal weight functions, the stress intensity factors are computed for the above interface crack problems when subjected to an instantaneous heat source.

Spectral Finite Element Formulation for Nanorods via Nonlocal Continuum Mechanics

In this article, the Eringen's nonlocal elasticity theory has been incorporated into classical/local Bernoulli-Euler rod model to capture unique properties of the nanorods under the umbrella of continuum mechanics theory. The spectral finite element (SFE) formulation of nanorods is performed. SFE formulation is carried out and the exact shape functions (frequency dependent) and dynamic stiffness matrix are obtained as function of nonlocal scale parameter. It has been found that the small scale affects the exact shape functions and the elements of the dynamic stiffness matrix. The results presented in this paper can provide useful guidance for the study and design of the next generation of nanodevices that make use of the wave dispersion properties of carbon nanotubes.

Analysis of Lined Ducts With Mean Flow, With Application to Dissipative Mufflers

Mufflers with at least one acoustically absorptive duct are generally called dissipative mufflers. Generally, for want of systems approach, these mufflers are characterized by transmission loss of the lined duct with overriding corrections for the terminations, mean flow, etc. In this article, it is proposed that dissipative duct should be integrated with other muffler elements, source impedance and radiation impedance, by means of transfer matrix approach. Towards this end, the transfer matrix for rectangular duct with mean flow has been derived here, for the least attenuated mode. Mean flow introduces a coupling between transverse wave numbers and axial wave number, the evaluation of which therefore calls for simultaneous solution of two or three transcendental equations. This is done by means of a Newton-Raphson iteration scheme, which is illustrated here for square ducts lined with porous ceramic tiles.

Investigation on the High Vacuum Tribological Characteristics of Surface Treated Nuclear Grade Stainless Steel Type AISI 316 LN at 25 to 500 degrees C

Although some researchers have published friction and wear data of Plasma Nitride (PN) coatings, the tribological behavior of PN/PN Pairs in high vacuum environment has not been published so far In order to bridge this knowledge gap, tribological tests under dry conditions have been conducted on PN/PN Pairs for varying temperatures of 25, 200, 400 and 500 degrees C in high vacuum (1.6 x 10(-4) bar) environment. The PN coatings showed good wear resistance layer on the ring surface. The PN coatings were removed only from the pin surface for all the tests since it contacts at a point. The friction and wear were low at lower temperatures and it eliminated adhesion between the contact surfaces until the coating was completely removed from the pin surface. (C) 2011 Journal of Mechanical Engineering. All rights reserved.

Viscous effects in the inception of cavitation

The inception of cavitation in the steady flow of liquids around bodies is seen to depend upon the real fluid flow around the bodies as well as the supply of nucleating cavitation sources—or nuclei—within the fluid. A primary distinction is made between bodies having a laminar separation or not having a laminar separation. The former group is relatively insensitive to the nuclei concentration whereas the latter is much more sensitive. Except for the case of fully separated wake flows and for gaseous cavitation by diffusion the cavitation inception index tends always to be less than the magnitude of the minimum pressure coefficient and only approaches that value for high Reynolds numbers in flows well supplied with nuclei.

Dry tribology and nanomechanics of gaseous flame soot in comparison with carbon black and diesel soot

Ethylene gas is burnt and the carbon soot particles are thermophoretically collected using a home-built equipment where the fuel air injection and intervention into the 7.5-cm long flame are controlled using three small pneumatic cylinders and computer-driven controllers. The physical and mechanical properties and tribological performance of the collected soot are compared with those of carbon black and diesel soot. The crystalline structures of the nanometric particles generated in the flame, as revealed by high-resolution transmission electron studies, are shown to vary from the flame root to the exhaust. As the particle journeys upwards the flame, through a purely amorphous coagulated phase at the burner nozzle, it leads to a well-defined crystalline phase shell in the mid-flame zone and to a disordered phase consisting of randomly distributed short-range crystalline order at the exhaust. In the mid-flame region, a large shell of radial-columnar order surrounds a dense amorphous core. The hardness and wear resistance as well as friction coefficient of the soot extracted from this zone are low. The mechanical properties characteristics of this zone may be attributed to microcrystalline slip. Moving towards the exhaust, the slip is inhibited and there is an increase in hardness and friction compared to those in the mid-flame zone. This study of the comparison of flame soot to carbon black and diesel soot is further extended to suggest a rationale based on additional physico-chemical study using micro-Raman spectroscopy.