Desenvolvimento de um núcleo versátil e integrado de ferramentas CAD/CAE para a modelagem e simulação de peças mecânicas

Currently there is still a high demand for quality control in manufacturing processes of mechanical parts. This keeps alive the need for the inspection activity of final products ranging from dimensional analysis to chemical composition of products. Usually this task may be done through various nondestructive and destructive methods that ensure the integrity of the parts. The result generated by these modern inspection tools ends up not being able to geometrically define the real damage and, therefore, cannot be properly displayed on a computing environment screen. Virtual 3D visualization may help identify damage that would hardly be detected by any other methods. One may find some commercial softwares that seek to address the stages of a design and simulation of mechanical parts in order to predict possible damages trying to diminish potential undesirable events. However, the challenge of developing softwares capable of integrating the various design activities, product inspection, results of non-destructive testing as well as the simulation of damage still needs the attention of researchers. This was the motivation to conduct a methodological study for implementation of a versatile CAD/CAE computer kernel capable of helping programmers in developing softwares applied to the activities of design and simulation of mechanics parts under stress. In this research it is presented interesting results obtained from the use of the developed kernel showing that it was successfully applied to case studies of design including parts presenting specific geometries, namely: mechanical prostheses, heat exchangers and piping of oil and gas. Finally, the conclusions regarding the experience of merging CAD and CAE theories to develop the kernel, so as to result in a tool adaptable to various applications of the metalworking industry are presented

Simulação do escoamento multifásico no interior de bombas de cavidades progressivas metálicas

The progressing cavity pumping (PCP) is one of the most applied oil lift methods nowadays in oil extraction due to its ability to pump heavy and high gas fraction flows. The computational modeling of PCPs appears as a tool to help experiments with the pump and therefore, obtain precisely the pump operational variables, contributing to pump s project and field operation otimization in the respectively situation. A computational model for multiphase flow inside a metallic stator PCP which consider the relative motion between rotor and stator was developed in the present work. In such model, the gas-liquid bubbly flow pattern was considered, which is a very common situation in practice. The Eulerian-Eulerian approach, considering the homogeneous and inhomogeneous models, was employed and gas was treated taking into account an ideal gas state. The effects of the different gas volume fractions in pump volumetric eficiency, pressure distribution, power, slippage flow rate and volumetric flow rate were analyzed. The results shown that the developed model is capable of reproducing pump dynamic behaviour under the multiphase flow conditions early performed in experimental works

Modelagem dinâmica do escoamento de um sistema de elevação por plunger lift

A critical problem in mature gas wells is the liquid loading. As the reservoir pressure decreases, gas superficial velocities decreases and the drag exerted on the liquid phase may become insufficient to bring all the liquid to the surface. Liquid starts to drain downward, flooding the well and increasing the backpressure which decreases the gas superficial velocity and so on. A popular method to remedy this problem is the Plunger Lift. This method consists of dropping the "plunger"to the bottom of the tubing well with the main production valve closed. When the plunger reaches the well bottom the production valve is opened and the plunger carry the liquid to the surface. However, models presented in literature for predicting the behavior in plunger lift are simplistic, in many cases static (not considering the transient effects). Therefore work presents the development and validation of a numerical algorithm to solve one-dimensional compressible in gas wells using the Finite Volume Method and PRIME techniques for treating coupling of pressure and velocity fields. The code will be then used to develop a dynamic model for the plunger lift which includes the transient compressible flow within the well

Medição e modelagem da resposta de um sensor de pig perfilométrico sob diferentes solicitações dinâmicas

Ensure the integrity of the pipeline network is an extremely important factor in the oil and gas industry. The engineering of pipelines uses sophisticated robotic inspection tools in-line known as instrumented pigs. Several relevant factors difficult the inspection of pipelines, especially in offshore field which uses pipelines with multi-diameters, radii of curvature accentuated, wall thickness of the pipe above the conventional, multi-phase flow and so on. Within this context, appeared a new instrumented Pig, called Feeler PIG, for detection and sizing of thickness loss in pipelines with internal damage. This tool was developed to overcome several limitations that other conventional instrumented pigs have during the inspection. Several factors influence the measurement errors of the pig affecting the reliability of the results. This work shows different operating conditions and provides a test rig for feeler sensors of an inspection pig under different dynamic loads. The results of measurements of the damage type of shoulder and holes in a cyclic flat surface are evaluated, as well as a mathematical model for the sensor response and their errors from the actual behavior

Otimização do fresamento de roscas internas com a técnica de interpolação helicoidal

In machining of internal threads, dedicated tools, known as taps, are needed for each profile type, diameter, and low cutting speed values are used when compared to main machining processes. This restriction in the cutting speed is associated with the difficulty of synchronizing the tool s rotation speed and feed velocity in the process. This fact restricts the flexibility and makes machining lead times longer when manufacturing of components with threads is required. An alternative to the constraints imposed by the tap is the thread milling with helical interpolation technique. The technique is the fusion of two movements: rotation and helical interpolation. The tools may have different configurations: a single edge or multiple edges (axial, radial or both). However, thread milling with helical interpolation technique is relatively new and there are limited studies on the subject, a fact which promotes challenges to its wide application in the manufacturing shop floor. The objective of this research is determine the performance of different types of tools in the thread milling with helical interpolation technique using hardened steel workpieces. In this sense, four tool configurations were used for threading milling in AISI 4340 quenched and tempered steel (40 HRC). The results showed that climb cut promoted a greater number of machined threads, regardless of tool configuration. The upcut milling causes chippings in cutting edge, while the climb cutting promotes abrasive wear. Another important point is that increase in hole diameter by tool diameter ratio increases tool lifetime

Otimização de sistema de bombeamento com energia eólica: sistema de bombeamento de São Gabriel/BA

After the Protocol of Kyoto and of the ECHO 92 - Rio de Janeiro, the attentions of the world focus to the preservation of the environment and of the maintainable use of the natural resources. People were looking for preserving environment for the future generations. Ever since, solutions are looked for the supply of energy in its more acquaintances forms and the substitution of the use of fossil fuels for the such alternative forms as: Photovoltaics, solar heat systems for water, wind , bio-diesel, etc. and in this context the Company of Engineering of the State of Bahia - Cerb changed a diesel pumping system by an wind one, It´s the first community system of this nature in Bahia. Facing problems with the model, a Cerb involved the academic segment of the Federal Center of Technological Education of Bahia Cefetba looking for a solution. This work intends to demonstrate the possibilities of optimization of the pumping communit system that supply water to approximately 50 people in the place of Romão, municipal district of São Gabriel-Ba. Technical reports were published in AGRENERGD2004-Unicamp SP and Scientific Magazine ETC,Cefetba, 2005. A simulation of the increase of energy is presented for heights of 15 and 20m, considering the eletromecanical balance from the pumping energy to the wind turbine. From the accomplished bibliographical revision, we emphasized the mechanical aspects of the engineering once in UFRN, those studies concentrate on the Department of Mechanical Engineering while, in others eletroelectronic are more emphasized. Finally, documents that we judged important were enclosed for the perfect understanding of this work

Obtenção de antioxidante a partir de derivados do LCC

Cashew-nut-shell-liquid (CNSL) is a phenolic oil that hás been due its their antioxirsion properties for use in fuels. The present work develops a method to the conversion of hidrogenated cardanol, that is the main component of the CNSL, in a compound with similar chacteristics to antioxidants used in products from petroleum. The antioxidants wasd obtained by exhaustive alkylation of the compound with tert-butyl chloride. After completing the optimization of several reaction steps, the product 2,4,6 tri-tert-butyl (pentadecylphenol) was obtained for the first tima. Characteeization and determination of physico-chemical properties were realized too, as well as wasd developed a study for check your application as an oxidative inhibitor by the molecular modeling. Estimation of process evalution was executed as well, where a rapid and practical computational methodology was utilizated in projects of the fine chemistry. The research showed satisfactory results and it could be concluded that the commercialization of this chemical products is feasible

Avaliação e modelagem reológica de fluido de perfuração base água

The determination of the rheology of drilling fluids is of fundamental importance to select the best composition and the best treatment to be applied in these fluids. This work presents a study of the rheological behavior of some addictives used as viscosifiers in water-based drilling fluids. The evaluated addictives were: Carboxymethylcellulose (CMC), Xanthan gum (GX), and Bentonite. The main objective was to rheologically characterize suspensions composed by these addictives, by applying mathematical models for fluid flow behavior, in order to determine the best flow equation to represent the system, as well as the model parameters. The mathematical models applied in this research were: the Bingham Model, the Ostwald de Wale Model, and the Herschel-Bulkley Model. A previous study of hydration time for each used addictive was accomplished seeking to evaluate the effect of polymer and clay hydration on rheological behavior of the fluid. The rheological characterization was made through typical rheology experiments, using a coaxial cylinder viscosimeter, where the flow curves and the thixotropic magnitude of each fluid was obtained. For each used addictive the rheological behavior as a function of temperature was also evaluated as well as fluid stability as a function of the concentration and kind of addictive used. After analyses of results, mixtures of polymer and clay were made seeking to evaluate the rheological modifications provided by the polymer incorporation in the water + bentonite system. The obtained results showed that the Ostwald de Waale model provided the best fit for fluids prepared using CMC and for fluids with Xanthan gum and Bentonite the best fit was given by the Herschel-Bulkley one

Otimização da injeção cíclica de vapor em reservatório de óleo pesado

Thermal methods made heavy oil production possible in fields where primary recovery failed. Throughout the years steam injection became one of the most important alternatives to increase heavy oil recovery. There are many types of steam injection, and one of them is the cyclic steam injection, which has been used with success in several countries, including Brazil. The process involves three phases: firstly, steam is injected, inside of the producing well; secondly, the well is closed (soak period); and finally, the well is put back into production. These steps constitute one cycle. The cycle is repeated several times until economical production limit is reached. Usually, independent of reservoir type, as the number of cycles increases the cyclic injection turns less efficient. This work aims to analyze rock and reservoir property influence in the cyclic steam injection. The objective was to study the ideal number of cycles and, consequently, process optimization. Simulations were realized using the STARS simulator from the CMG group based in a proposed reservoir model. It was observed that the reservoir thickness was the most important parameter in the process performance, whilst soaking time influence was not significant

Otimização do processo de recuperação do cromo de efluentes de curtumes por microemulsões no extrator Morris

The tanning industries are those which transform animal hide or skin into leather. Due to the complexity of the transformation process, greater quantities of chemicals are being used which results in the generation of effluents with residual solids. The chromium in the residual waters generated by tanning tend to be a serious problem to the environment, therefore the recovery of this metal could result in the reduction of manufacturing costs. This metal is usually found in a trivalent form which can be converted into a hexavalent compound under acidic conditions and in the presence of organic matter. The present study was carried out with the objective to recover chromium through an extraction/re-extraction process using micro emulsions. Micro emulsions are transparent and thermodynamically stable system composed of two immiscible liquids, one forming the continuous phase and the other dispersed into micro bubbles, established by an interfacial membrane formed by surface active and co-surface active molecules. The process of recovering the chromium was carried out in two stages. The first, an extraction process, where the chromium was extracted in the micro emulsion phase and the aqueous phase in excess was separated. In the second stage, a concentrated acid was added to the micro emulsion phase rich in chromium in order to obtain a Winsor II system, where the water that formed in the micro emulsion phase separates into a new micro emulsion phase with a higher concentration of chromium, due to the lowering of the hydrophiles as well as the ionisation of the system. During the experimental procedure, a study was initiated with a synthetic solution of chromium sulphate passing onto the effluent. A Morris extractor was used in the extraction process. Tests were carried out according to the plan and the results were analysed by statistical methods in order to optimise the main parameters that influence the process: the total rate of flow (Q), stirring speed (w) and solvent rate (r). The results, after optimization, demonstrated that the best percentuals in relation to the chromium extraction (99 %) were obtained in the following operational conditions: Q= 2,0 l/h, w= 425 rpm and r= 0,375. The re-extraction was carried out at room temperature (28 °C), 40 °C and 50°C using hydrochloric acid (8 and 10 M) and sulphuric acid (8 M) as re-extracting agents. The results obtained demonstrate that the process was efficient enough in relation to the chromium extraction, reaching to re-extraction percentage higher than 95 %.

Determinação experimental e modelagem termodinâmica do ponto de turbidez de sistemas aquosos com tensoativos nonilfenolpolietoxilados

The nonionic surfactants are composed of substances whose molecules in solution, does not ionize. The solubility of these surfactants in water due to the presence of functional groups that have strong affinity for water. When these surfactants are heated is the formation of two liquid phases, evidenced by the phenomenon of turbidity. This study was aimed to determine the experimental temperature and turbidity nonilfenolpoliethoxyled subsequently perform a thermodynamic modeling, considering the models of Flory-Huggins and the empirical solid-liquid equilibrium (SLE). The method used for determining the turbidity point was the visual method (Inoue et al., 2008). The experimental methodology consisted of preparing synthetic solutions of 0,25%, 0,5%, 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, 12,5%, 15%, 17% and 20% by weight of surfactant. The nonionic surfactants used according to their degree of ethoxylation (9.5, 10, 11, 12 and 13). During the experiments the solutions were homogenized and the bath temperature was gradually increased while the turbidity of the solution temperature was checked visually Inoue et al. (2003). These temperature data of turbidity were used to feed the models evaluated and obtain thermodynamic parameters for systems of surfactants nonilfenolpoliethoxyled. Then the models can be used in phase separation processes, facilitating the extraction of organic solvents, therefore serve as quantitative and qualitative parameters. It was observed that the solidliquid equilibrium model (ESL) was best represented the experimental data.

Caracterização de água produzida na indústria de petróleo para fins de descarte e otimização do processo de separação óleo/água

The oil industry has several segments that can impact the environment. Among these, produced water which has been highlight in the environmental problem because of the great volume generated and its toxic composition. Those waters are the major source of waste in the oil industry. The composition of the produced water is strongly dependent on the production field. A good example is the wastewater produced on a Petrobras operating unit of Rio Grande do Norte and Ceará (UO-RNCE). A single effluent treatment station (ETS) of this unit receives effluent from 48 wells (onshore and offshore), which leads a large fluctuations in the water quality that can become a complicating factor for future treatment processes. The present work aims to realize a diagnosis of a sample of produced water from the OU - RNCE in compliance to certain physical and physico-chemical parameters (chloride concentration, conductivity, dissolved oxygen, pH, TOG (oil & grease), nitrate concentration, turbidity, salinity and temperature). The analysis of the effluent is accomplished by means of a MP TROLL 9500 Multiparameter probe, a TOG/TPH Infracal from Wilks Enterprise Corp. - Model HATR - T (TOG) and a MD-31 condutivimeter of Digimed. Results were analyzed by univariated and multivariated analysis (principal component analysis) associated statistical control charts. The multivariate analysis showed a negative correlation between dissolved oxygen and turbidity (-0.55) and positive correlations between salinity and chloride (1), conductivity, chloride and salinity (0.70). Multivariated analysis showed there are seven principal components which can explain the variability of the parameters. The variables, salinity, conductivity and chloride were the most important variables, with, higher sampling variance. Statistical control charts have helped to establish a general trend between the physical and chemical evaluated parameters

Modelagem e simulação da deposição de parafinas em escoamento turbulento

The flow assurance has become one of the topics of greatest interest in the oil industry, mainly due to production and transportation of oil in regions with extreme temperature and pressure. In these operations the wax deposition is a commonly problem in flow of paraffinic oils, causing the rising costs of the process, due to increased energy cost of pumping, decreased production, increased pressure on the line and risk of blockage of the pipeline. In order to describe the behavior of the wax deposition phenomena in turbulent flow of paraffinic oils, under different operations conditions, in this work we developed a simulator with easy interface. For that we divided de work in four steps: (i) properties estimation (physical, thermals, of transport and thermodynamics) of n-alkanes and paraffinic mixtures by using correlations; (ii) obtainment of the solubility curve and determination the wax appearance temperature, by calculating the solid-liquid equilibrium of parafinnic systems; (iii) modelling wax deposition process, comprising momentum, mass and heat transfer; (iv) development of graphic interface in MATLAB® environment for to allow the understanding of simulation in different flow conditions as well as understand the matter of the variables (inlet temperature, external temperature, wax appearance temperature, oil composition, and time) on the behavior of the deposition process. The results showed that the simulator developed, called DepoSim, is able to calculate the profile of temperature, thickness of the deposit, and the amount of wax deposited in a simple and fast way, and also with consistent results and applicable to the operation

Modelagem da transferência de massa na remoção do óleo da água produzida por flotação em coluna com uso de tensoativos de origem vegetal

The treatment of oil produced water and its implications are continually under investigation and several questions are related to this subject. In the Northeast Region Brazil, the onshore reservoirs are, in its majority, mature oil fields with high production of water. As this oil produced water has high levels of oil, it cannot be directly discarded into the environment because it represents a risk for contamination of soil, water, and groundwater, or even may cause harm to living bodies. Currently, polyelectrolytes that promote the coalescence of the oil droplets are used to remove the dispersed oil phase, enhancing the effectiveness of the flotation process. The non-biodegradability and high cost of polyelectrolytes are limiting factors for its application. On this context, it is necessary to develop studies for the search of more environmentally friendly products to apply in the flotation process. In this work it is proposed the modeling of the flotation process, in a glass column, using surfactants derived from vegetal oils to replace the polyelectrolytes, as well as to obtain a model that represents the experimental data. In addition, it was made a comparative study between the models described in the literature and the one developed in this research. The obtained results showed that the developed model presented high correlation coefficients when fitting the experimental data (R2 > 0.98), thus proving its efficiency in modeling the experimental data.

Otimização do tempo e temperatura no processamento da gipsita oriunda dos cristalizadores da produção de sal para obter gesso de uso na construção civil

During the process of the salt production, the first the salt crystals formed are disposed of as industrial waste. This waste is formed basically by gypsum, composed of calcium sulfate dihydrate (CaSO4.2H2O), known as carago cru or malacacheta . After be submitted the process of calcination to produce gypsum (CaSO4.0,5H2O), can be made possible its application in cement industry. This work aims to optimize the time and temperature for the process of calcination of the gypsum (carago) for get beta plaster according to the specifications of the norms of civil construction. The experiments involved the chemical and mineralogical characterization of the gypsum (carago) from the crystallizers, and of the plaster that is produced in the salt industry located in Mossoró, through the following techniques: x-ray diffraction (XRD), x-ray fluorescence (FRX), thermogravimetric analysis (TG/DTG) and scanning electron microscopy (SEM) with EDS. For optimization of time and temperature of the process of calcination was used the planning three factorial with levels with response surfaces of compressive mechanical tests and setting time, according norms NBR-13207: Plasters for civil construction and x-ray diffraction of plasters (carago) beta obtained in calcination. The STATISTICA software 7.0 was used for the calculations to relate the experimental data for a statistical model. The process for optimization of calcination of gypsum (carago) occurred in the temperature range from 120° C to 160° C and the time in the range of 90 to 210 minutes in the oven at atmospheric pressure, it was found that with the increase of values of temperature of 160° C and time calcination of 210 minutes to get the results of tests of resistance to compression with values above 10 MPa which conform to the standard required (> 8.40) and that the X-ray diffractograms the predominance of the phase of hemidrato beta, getting a beta plaster of good quality and which is in accordance with the norms in force, giving a by-product of the salt industry employability in civil construction