Pub Date : 2024-05-17DOI: 10.3389/fmech.2024.1360502
R. Honkalas, Bhagyesh Deshmukh, P. Pawar, Sachin Salunkhe, R. Čep, Emad S. Abouel Nasr
The present design of a set of worm gears used in a soot blower produced by a certain manufacturer has an efficiency of 68.8%. A soot blower is one of the most critical components in industrial applications for removing the large amounts of soot generated by boilers and is required to be operational 24×7. The energy consumption of the soot blower depends on its working efficiency and ultimately the design of its set of worm gears. This paper focuses mainly on the design and analysis of available industrial worm-gear sets used in soot blowers. The theoretical, experimental, and finite-element analysis approaches are validated for the stability of the worm gear set under typical input conditions. This paper also describes an analytical design of experiments (DOE) approach to identify the most significant factor for performance (efficiency) improvement and suggests some design improvements for the worm gear set using the profile modification approach. These ensure the efficiency improvement of the current industrial design of the set of worm gears used in a soot blower. The analytical DOE approach helped identify that the number of worm wheel teeth (Z2) and gear module (m) are the two most significant factors affecting performance. Accordingly, based on the improved design, the final efficiency increased from 68.8% to 74.6% (∼8.5% increment), resulting in lower power consumption during industrial application.
{"title":"Performance improvement of set of worm gears used in soot blower through profile modification","authors":"R. Honkalas, Bhagyesh Deshmukh, P. Pawar, Sachin Salunkhe, R. Čep, Emad S. Abouel Nasr","doi":"10.3389/fmech.2024.1360502","DOIUrl":"https://doi.org/10.3389/fmech.2024.1360502","url":null,"abstract":"The present design of a set of worm gears used in a soot blower produced by a certain manufacturer has an efficiency of 68.8%. A soot blower is one of the most critical components in industrial applications for removing the large amounts of soot generated by boilers and is required to be operational 24×7. The energy consumption of the soot blower depends on its working efficiency and ultimately the design of its set of worm gears. This paper focuses mainly on the design and analysis of available industrial worm-gear sets used in soot blowers. The theoretical, experimental, and finite-element analysis approaches are validated for the stability of the worm gear set under typical input conditions. This paper also describes an analytical design of experiments (DOE) approach to identify the most significant factor for performance (efficiency) improvement and suggests some design improvements for the worm gear set using the profile modification approach. These ensure the efficiency improvement of the current industrial design of the set of worm gears used in a soot blower. The analytical DOE approach helped identify that the number of worm wheel teeth (Z2) and gear module (m) are the two most significant factors affecting performance. Accordingly, based on the improved design, the final efficiency increased from 68.8% to 74.6% (∼8.5% increment), resulting in lower power consumption during industrial application.","PeriodicalId":53220,"journal":{"name":"Frontiers in Mechanical Engineering","volume":null,"pages":null},"PeriodicalIF":2.3,"publicationDate":"2024-05-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140963848","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-05-15DOI: 10.3389/fmech.2024.1396170
Radharaman Tripathi, Tushar A. Jadhav, Mahesh K. Gaikwad, Mithul J. Naidu, Aishwarya B. Gawand, Duran Kaya, Sachin Salunkhe, R. Čep, Emad S. Abouel Nasr
The piping system connected with the shipboard equipment may be subjected to excessive vibration due to harmonic base excitation produced by hydrodynamic force imposed on the propeller blades interacting with the hull and by other sources. Vibration design aspects for shipboard pipework are often ignored, which may cause catastrophic fatigue failures and, consequently, leakage and spillage in the sea environment. Without dedicated design codes, the integrity of shipboard equipment against this environment loading can be ensured by testing as per test standard MIL-STD-167-1A (2005). However, in many cases, testing is not feasible and economically viable. Hence, this study develops an FE-based vibration analysis methodology based on MIL-STD-167-1A, which can be a valuable tool to optimize the testing requirement without compromising the integrity of these piping systems. The simulated model dynamic properties are validated with experimental modal testing and Harmonic response analysis result confirm that a mitigating solution option can be verified by a FE based vibration analysis to mitigate the vibration problem.
{"title":"Vibration analysis of piping connected with shipboard equipment","authors":"Radharaman Tripathi, Tushar A. Jadhav, Mahesh K. Gaikwad, Mithul J. Naidu, Aishwarya B. Gawand, Duran Kaya, Sachin Salunkhe, R. Čep, Emad S. Abouel Nasr","doi":"10.3389/fmech.2024.1396170","DOIUrl":"https://doi.org/10.3389/fmech.2024.1396170","url":null,"abstract":"The piping system connected with the shipboard equipment may be subjected to excessive vibration due to harmonic base excitation produced by hydrodynamic force imposed on the propeller blades interacting with the hull and by other sources. Vibration design aspects for shipboard pipework are often ignored, which may cause catastrophic fatigue failures and, consequently, leakage and spillage in the sea environment. Without dedicated design codes, the integrity of shipboard equipment against this environment loading can be ensured by testing as per test standard MIL-STD-167-1A (2005). However, in many cases, testing is not feasible and economically viable. Hence, this study develops an FE-based vibration analysis methodology based on MIL-STD-167-1A, which can be a valuable tool to optimize the testing requirement without compromising the integrity of these piping systems. The simulated model dynamic properties are validated with experimental modal testing and Harmonic response analysis result confirm that a mitigating solution option can be verified by a FE based vibration analysis to mitigate the vibration problem.","PeriodicalId":53220,"journal":{"name":"Frontiers in Mechanical Engineering","volume":null,"pages":null},"PeriodicalIF":2.3,"publicationDate":"2024-05-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140972763","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-05-14DOI: 10.3389/fmech.2024.1368683
Xinping Wu, Rongnian He, Han Ge, Mengyu Chen
Introduction: As science and technology develop, automobiles are moving toward intelligence and electrification and need better braking systems.Methods: To improve the braking system’s response speed and braking effect, a longitudinal dynamics control system for automobiles based on the electronic mechanical braking system was proposed, and the electronic mechanical braking system was improved through automatic disturbance rejection control.Results: The experimental results show that the time required for achieving the target clamping force in the electronic mechanical braking system using self-disturbance rejection control and proportional integral differential control is only 0.01 s, but there is an issue of excessive control in the proportional integral differential system between 0.12 s and 0.2 s, while the self-disturbance rejection controller does not have this problem. Meanwhile, regardless of the interference applied, the electronic mechanical braking system with automatic disturbance rejection control can ensure that the clamping force does not fluctuate. In the joint simulation experiment, the expected acceleration and actual acceleration can remain consistent, and if the expected braking force is 9000 N, then the actual braking force of the electronic mechanical brake (EMB) is also 9000 N.Discussion: The above results indicate that the vehicle longitudinal dynamics control system using the electronic mechanical braking system not only responds fast but also has a good braking effect, avoiding the problem of excessive control and improving the driving experience.
引言随着科学技术的发展，汽车正朝着智能化和电气化的方向发展，需要更好的制动系统：方法：为了提高制动系统的响应速度和制动效果，提出了一种基于电子机械制动系统的汽车纵向动力学控制系统，并通过自动干扰抑制控制对电子机械制动系统进行了改进：实验结果表明，采用自扰动抑制控制和比例积分微分控制的电子机械制动系统达到目标夹紧力所需的时间仅为 0.01 s，但比例积分微分系统在 0.12 s 至 0.2 s 之间存在控制过度的问题，而自扰动抑制控制器则不存在这一问题。同时，无论施加何种干扰，带有自动干扰抑制控制的电子机械制动系统都能确保夹紧力不波动。在联合仿真实验中，预期加速度和实际加速度可以保持一致，如果预期制动力为 9000 N，那么电子机械式制动器（EMB）的实际制动力也为 9000 N：以上结果表明，使用电子机械制动系统的车辆纵向动力学控制系统不仅响应速度快，而且制动效果好，避免了过度控制的问题，改善了驾驶体验。
{"title":"Electronic mechanical braking system executive mechanism design, calculation, and modeling based on dynamic control","authors":"Xinping Wu, Rongnian He, Han Ge, Mengyu Chen","doi":"10.3389/fmech.2024.1368683","DOIUrl":"https://doi.org/10.3389/fmech.2024.1368683","url":null,"abstract":"Introduction: As science and technology develop, automobiles are moving toward intelligence and electrification and need better braking systems.Methods: To improve the braking system’s response speed and braking effect, a longitudinal dynamics control system for automobiles based on the electronic mechanical braking system was proposed, and the electronic mechanical braking system was improved through automatic disturbance rejection control.Results: The experimental results show that the time required for achieving the target clamping force in the electronic mechanical braking system using self-disturbance rejection control and proportional integral differential control is only 0.01 s, but there is an issue of excessive control in the proportional integral differential system between 0.12 s and 0.2 s, while the self-disturbance rejection controller does not have this problem. Meanwhile, regardless of the interference applied, the electronic mechanical braking system with automatic disturbance rejection control can ensure that the clamping force does not fluctuate. In the joint simulation experiment, the expected acceleration and actual acceleration can remain consistent, and if the expected braking force is 9000 N, then the actual braking force of the electronic mechanical brake (EMB) is also 9000 N.Discussion: The above results indicate that the vehicle longitudinal dynamics control system using the electronic mechanical braking system not only responds fast but also has a good braking effect, avoiding the problem of excessive control and improving the driving experience.","PeriodicalId":53220,"journal":{"name":"Frontiers in Mechanical Engineering","volume":null,"pages":null},"PeriodicalIF":2.3,"publicationDate":"2024-05-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140977836","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-05-10DOI: 10.3389/fmech.2024.1371218
Hongqiang Guan
Introduction: The dynamic positioning system resists the environmental forces such as wind, wave and current acting on the ship through the thruster, so that the ship can remain in the position required by the sea level as much as possible, and the operation is very convenient. But its current dynamic positioning ability can not meet people's needs.Methods: A Kalman filter based on untracked optimization was designed for dynamic positioning control system. Then the intelligent control algorithm is designed for the dynamic positioning top-level controller and thrust optimal distribution controller, which occupy an important position in the system, namely the adaptive weight variation particle swarm optimization algorithm and thrust optimal distribution algorithm.Results and Discussion: The average position error of three degrees of freedom after filter processing is 1.53 m. Compared with other mainstream controllers, the mean root error of controllers based on adaptive weight variation particle swarm optimization in environment A and B is 2.295 and 1.8 m, respectively. In environment C, the controller based on thrust optimization allocation algorithm can get the optimal solution when the full rotary thruster reaches the 7 s and the channel thruster reaches the 4 s. The thrust exclusion zone is crossed at 46 s in environment D. In the dynamic positioning capability curve of the system, the experimental hull can balance the different environmental loads at all angles. In summary, the intelligent control algorithm proposed in this paper can effectively improve the positioning ability of the dynamic positioning control system and meet the needs of people for ship navigation today.
简介动态定位系统通过推进器抵抗作用在船舶上的风、浪、流等环境力，使船舶尽可能保持在海平面要求的位置，操作十分方便。但其目前的动态定位能力还不能满足人们的需求：方法：为动态定位控制系统设计了基于无轨优化的卡尔曼滤波器。方法：为动态定位控制系统设计了基于无轨优化的卡尔曼滤波器，然后为在系统中占据重要地位的动态定位顶层控制器和推力优化分布控制器设计了智能控制算法，即自适应权值变化粒子群优化算法和推力优化分布算法：与其他主流控制器相比，基于自适应权变粒子群优化算法的控制器在环境 A 和 B 中的平均根误差分别为 2.295 米和 1.8 米。在环境 C 中，基于推力优化分配算法的控制器可以在全回转推进器达到 7 s、通道推进器达到 4 s 时获得最优解。综上所述，本文提出的智能控制算法能有效提高动态定位控制系统的定位能力，满足当今人们对船舶导航的需求。
{"title":"Intelligent control algorithm for dynamic positioning control system","authors":"Hongqiang Guan","doi":"10.3389/fmech.2024.1371218","DOIUrl":"https://doi.org/10.3389/fmech.2024.1371218","url":null,"abstract":"Introduction: The dynamic positioning system resists the environmental forces such as wind, wave and current acting on the ship through the thruster, so that the ship can remain in the position required by the sea level as much as possible, and the operation is very convenient. But its current dynamic positioning ability can not meet people's needs.Methods: A Kalman filter based on untracked optimization was designed for dynamic positioning control system. Then the intelligent control algorithm is designed for the dynamic positioning top-level controller and thrust optimal distribution controller, which occupy an important position in the system, namely the adaptive weight variation particle swarm optimization algorithm and thrust optimal distribution algorithm.Results and Discussion: The average position error of three degrees of freedom after filter processing is 1.53 m. Compared with other mainstream controllers, the mean root error of controllers based on adaptive weight variation particle swarm optimization in environment A and B is 2.295 and 1.8 m, respectively. In environment C, the controller based on thrust optimization allocation algorithm can get the optimal solution when the full rotary thruster reaches the 7 s and the channel thruster reaches the 4 s. The thrust exclusion zone is crossed at 46 s in environment D. In the dynamic positioning capability curve of the system, the experimental hull can balance the different environmental loads at all angles. In summary, the intelligent control algorithm proposed in this paper can effectively improve the positioning ability of the dynamic positioning control system and meet the needs of people for ship navigation today.","PeriodicalId":53220,"journal":{"name":"Frontiers in Mechanical Engineering","volume":null,"pages":null},"PeriodicalIF":2.3,"publicationDate":"2024-05-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140990967","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-05-09DOI: 10.3389/fmech.2024.1404116
Devendra G. Pendokhare, Kanak Kalita, Shankar Chakraborty, R. Čep
Optimization of electrical discharge machining (EDM) processes is a critical issue due to complex material removal mechanism, presence of multiple input parameters and responses (outputs) and interactions among them and varying interest of different stakeholders with respect to relative importance assigned to the considered responses. Multi-criteria decision making (MCDM) techniques have become potent tools in solving parametric optimization problems of the EDM processes. In this paper, more than 130 research articles from SCOPUS database published during 2013–22 are reviewed extracting information with respect to experimental design plans employed, materials machined, dielectrics used, process parameters and responses considered and MCDM tools applied along with their integration with other mathematical techniques. A detailed analysis of those reviewed articles reveals that the past researchers have mostly preferred Taguchi’s L9 orthogonal array as the experimental design plan; EDM oil as the dielectric fluid; medium and high carbon steels as the work materials; peak current and pulse-on time as the input parameters; material removal rate, tool wear rate and surface roughness as the responses; and grey relational analysis as the MCDM tool during conducting and optimizing EDM operations. This review paper would act as a data repository to the future researchers in understanding the stochastic behaviour of EDM processes and providing guidance in setting the tentative operating levels of varying input parameters along with achievable response values. The extracted dataset can be treated as an input to any of the machine learning algorithms for subsequent development of appropriate prediction models. This review also outlines potential future research avenues, emphasizing advancements in EDM technology and the integration of innovative multi-criteria decision-making tools.
{"title":"A comprehensive review of parametric optimization of electrical discharge machining processes using multi-criteria decision-making techniques","authors":"Devendra G. Pendokhare, Kanak Kalita, Shankar Chakraborty, R. Čep","doi":"10.3389/fmech.2024.1404116","DOIUrl":"https://doi.org/10.3389/fmech.2024.1404116","url":null,"abstract":"Optimization of electrical discharge machining (EDM) processes is a critical issue due to complex material removal mechanism, presence of multiple input parameters and responses (outputs) and interactions among them and varying interest of different stakeholders with respect to relative importance assigned to the considered responses. Multi-criteria decision making (MCDM) techniques have become potent tools in solving parametric optimization problems of the EDM processes. In this paper, more than 130 research articles from SCOPUS database published during 2013–22 are reviewed extracting information with respect to experimental design plans employed, materials machined, dielectrics used, process parameters and responses considered and MCDM tools applied along with their integration with other mathematical techniques. A detailed analysis of those reviewed articles reveals that the past researchers have mostly preferred Taguchi’s L9 orthogonal array as the experimental design plan; EDM oil as the dielectric fluid; medium and high carbon steels as the work materials; peak current and pulse-on time as the input parameters; material removal rate, tool wear rate and surface roughness as the responses; and grey relational analysis as the MCDM tool during conducting and optimizing EDM operations. This review paper would act as a data repository to the future researchers in understanding the stochastic behaviour of EDM processes and providing guidance in setting the tentative operating levels of varying input parameters along with achievable response values. The extracted dataset can be treated as an input to any of the machine learning algorithms for subsequent development of appropriate prediction models. This review also outlines potential future research avenues, emphasizing advancements in EDM technology and the integration of innovative multi-criteria decision-making tools.","PeriodicalId":53220,"journal":{"name":"Frontiers in Mechanical Engineering","volume":null,"pages":null},"PeriodicalIF":2.3,"publicationDate":"2024-05-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140996830","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-05-07DOI: 10.3389/fmech.2024.1390335
Y. Chen, J. Horng
The generation of third particles and change in viscosity lead to the gradual degradation of the performance of the machine interface. The generation of third particles may come from wear debris or environmental particles, which form a three-body contact system at the contact interface. The viscosity of the lubricant will also change with the long-term operation of the components. This paper uses a three-body lubrication model to study the influence and interaction of lubricant viscosity change and the presence of third particles on the contact characteristics, including the real contact area, the particle contact area ratio, the solid load percentage, the film thickness, and the evolution of the lubrication regime. The results show that when the interface is in a three-body mixed lubrication regime, the dimensionless total real contact area increases with the increase in particle size and density at the same lubricant viscosity, while the trend is the opposite in dry contact and boundary lubrication interfaces. When viscosity decreases, a three-body contact interface is more prone to entering boundary lubrication than a two-body contact interface, resulting in surface damage. Regardless of surface roughness, particle size, and dry or lubricated contact conditions, the turning point of the contact area (TPCA) phenomenon is usually when the ratio of particle size to surface roughness is 0.8–1.3. Under the same ratio of particle size to surface roughness, the critical load of the TPCA phenomenon increases with the increase in third-particle size and surface roughness, but decreases with the increase in lubricant viscosity and particle density.
{"title":"Investigation of lubricant viscosity and third-particle contribution to contact behavior in dry and lubricated three-body contact conditions","authors":"Y. Chen, J. Horng","doi":"10.3389/fmech.2024.1390335","DOIUrl":"https://doi.org/10.3389/fmech.2024.1390335","url":null,"abstract":"The generation of third particles and change in viscosity lead to the gradual degradation of the performance of the machine interface. The generation of third particles may come from wear debris or environmental particles, which form a three-body contact system at the contact interface. The viscosity of the lubricant will also change with the long-term operation of the components. This paper uses a three-body lubrication model to study the influence and interaction of lubricant viscosity change and the presence of third particles on the contact characteristics, including the real contact area, the particle contact area ratio, the solid load percentage, the film thickness, and the evolution of the lubrication regime. The results show that when the interface is in a three-body mixed lubrication regime, the dimensionless total real contact area increases with the increase in particle size and density at the same lubricant viscosity, while the trend is the opposite in dry contact and boundary lubrication interfaces. When viscosity decreases, a three-body contact interface is more prone to entering boundary lubrication than a two-body contact interface, resulting in surface damage. Regardless of surface roughness, particle size, and dry or lubricated contact conditions, the turning point of the contact area (TPCA) phenomenon is usually when the ratio of particle size to surface roughness is 0.8–1.3. Under the same ratio of particle size to surface roughness, the critical load of the TPCA phenomenon increases with the increase in third-particle size and surface roughness, but decreases with the increase in lubricant viscosity and particle density.","PeriodicalId":53220,"journal":{"name":"Frontiers in Mechanical Engineering","volume":null,"pages":null},"PeriodicalIF":2.3,"publicationDate":"2024-05-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141003120","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-05-02DOI: 10.3389/fmech.2024.1376038
Taemin Kim, A. Boehman
Soy-based biodiesel can reduce well-to-wheels greenhouse gas (GHG) emissions per unit energy (i.e., gCO2e/MJ) by 66%–72% as compared to the petroleum-based diesel fuel with currently adopted agricultural and industrial practices. Biodiesel can reduce particulate matter and carbon monoxide emissions with a manageable degree of increase in NOx emissions. From the perspective of GHG emissions reduction per unit travelling distance (i.e., gCO2e/mile), the application of B20 in compression ignition engines without the adjustment in engine control unit (ECU) settings will not extract the best carbon emissions reduction that B20 could achieve. Optimizing the engine control settings permits re-calibration to achieve the maximum brake fuel conversion efficiency (BFE) based on comprehensive understanding on the impact of both “fuel” and “ECU calibration” on BFE and other criteria pollutant emissions. The maximum GHG emissions reduction with B20 application is experimentally measured with the optimized ECU calibration, thus providing the understanding of the combined impact of biodiesel fuel and calibrations on engine performance and emissions. Six steady operating modes were considered, that can be combined to estimate the US federal test procedure BFE and emissions over the Federal Test Protocol (FTP) 75 cycle. Combined with the weight factors to simulate the EPA FTP 75 cycle from these 6 “mini-map” test points, 0.53% improvement in the energy requirement per unit traveling distance (i.e., MJ/mile) is achieved for B20 with the final ECU calibration, in addition to the degree of GHG emissions reduction on a “gCO2e/MJ” basis from the use of B20 blend of soy biodiesel of ∼12.5% reduction in gCO2e/MJ, for a total GHG emissions reduction of 13%.
{"title":"Greenhouse gas reduction in a medium-duty compression ignition engine with optimization for B20","authors":"Taemin Kim, A. Boehman","doi":"10.3389/fmech.2024.1376038","DOIUrl":"https://doi.org/10.3389/fmech.2024.1376038","url":null,"abstract":"Soy-based biodiesel can reduce well-to-wheels greenhouse gas (GHG) emissions per unit energy (i.e., gCO2e/MJ) by 66%–72% as compared to the petroleum-based diesel fuel with currently adopted agricultural and industrial practices. Biodiesel can reduce particulate matter and carbon monoxide emissions with a manageable degree of increase in NOx emissions. From the perspective of GHG emissions reduction per unit travelling distance (i.e., gCO2e/mile), the application of B20 in compression ignition engines without the adjustment in engine control unit (ECU) settings will not extract the best carbon emissions reduction that B20 could achieve. Optimizing the engine control settings permits re-calibration to achieve the maximum brake fuel conversion efficiency (BFE) based on comprehensive understanding on the impact of both “fuel” and “ECU calibration” on BFE and other criteria pollutant emissions. The maximum GHG emissions reduction with B20 application is experimentally measured with the optimized ECU calibration, thus providing the understanding of the combined impact of biodiesel fuel and calibrations on engine performance and emissions. Six steady operating modes were considered, that can be combined to estimate the US federal test procedure BFE and emissions over the Federal Test Protocol (FTP) 75 cycle. Combined with the weight factors to simulate the EPA FTP 75 cycle from these 6 “mini-map” test points, 0.53% improvement in the energy requirement per unit traveling distance (i.e., MJ/mile) is achieved for B20 with the final ECU calibration, in addition to the degree of GHG emissions reduction on a “gCO2e/MJ” basis from the use of B20 blend of soy biodiesel of ∼12.5% reduction in gCO2e/MJ, for a total GHG emissions reduction of 13%.","PeriodicalId":53220,"journal":{"name":"Frontiers in Mechanical Engineering","volume":null,"pages":null},"PeriodicalIF":2.3,"publicationDate":"2024-05-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141020311","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-04-24DOI: 10.3389/fmech.2024.1393088
Getachew Gebreamlak, Sivaprakasam Palani, Belete Sirahbizu, R. Čep
Additive mixed friction stir welding can be an innovative and novel method for enhancing the friction stir welding process. Thus, this research aimed to investigate nano Al2O3 effects on the mechanical and microstructure of FSWed joints using Al alloys AA2024-T351/AA7075-T651. The experiments were performed based on response surface approach based CCD twenty run with varying three factors: tool rotational speed (A: 800–1,200 rpm), welding speed (B: 20–60 mm/min), tool plunge depth (C: 0.2–0.4 mm) and fixed volume percentages of Al2O3 nano-particles (8%). Mechanical performances such as tensile, yield, and hardness tests have been performed and microstructural properties have been analyzed through SEM and microscopy. The statistical analysis shows that the tensile strength can be significantly affected by rotational speed (A), welding speed (B), tool plunge depth (C), interaction (AB, BC, AC), and quadratic term A2, B2 in the FSW process; yield strength was influenced considerably by main, interaction, and quadratic terms; main factors and quadratic terms A2, B2 and C2 significantly influenced hardness values. The fracture test revealed that the joints with Al2O3-reinforced AA2024-T351/AA7075-T651 alloys were more ductile and less brittle. The optimal conditions for FSW, tool rotational at 1,146 rpm, weld speed at 60 mm/min, and 0.4 mm plunge depth were responsible for higher tensile strength of 169 MPa, yield strength of 145 MPa, and micro-hardness values of 89 HRB due to the uniform nano-particle dispersions and better material mixing.
{"title":"Experimental investigation and optimization of nano Al2O3 mixed FSWed joint between AA2024-T351 and AA7075-T651 by response surface approach","authors":"Getachew Gebreamlak, Sivaprakasam Palani, Belete Sirahbizu, R. Čep","doi":"10.3389/fmech.2024.1393088","DOIUrl":"https://doi.org/10.3389/fmech.2024.1393088","url":null,"abstract":"Additive mixed friction stir welding can be an innovative and novel method for enhancing the friction stir welding process. Thus, this research aimed to investigate nano Al2O3 effects on the mechanical and microstructure of FSWed joints using Al alloys AA2024-T351/AA7075-T651. The experiments were performed based on response surface approach based CCD twenty run with varying three factors: tool rotational speed (A: 800–1,200 rpm), welding speed (B: 20–60 mm/min), tool plunge depth (C: 0.2–0.4 mm) and fixed volume percentages of Al2O3 nano-particles (8%). Mechanical performances such as tensile, yield, and hardness tests have been performed and microstructural properties have been analyzed through SEM and microscopy. The statistical analysis shows that the tensile strength can be significantly affected by rotational speed (A), welding speed (B), tool plunge depth (C), interaction (AB, BC, AC), and quadratic term A2, B2 in the FSW process; yield strength was influenced considerably by main, interaction, and quadratic terms; main factors and quadratic terms A2, B2 and C2 significantly influenced hardness values. The fracture test revealed that the joints with Al2O3-reinforced AA2024-T351/AA7075-T651 alloys were more ductile and less brittle. The optimal conditions for FSW, tool rotational at 1,146 rpm, weld speed at 60 mm/min, and 0.4 mm plunge depth were responsible for higher tensile strength of 169 MPa, yield strength of 145 MPa, and micro-hardness values of 89 HRB due to the uniform nano-particle dispersions and better material mixing.","PeriodicalId":53220,"journal":{"name":"Frontiers in Mechanical Engineering","volume":null,"pages":null},"PeriodicalIF":2.3,"publicationDate":"2024-04-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140662226","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-04-19DOI: 10.3389/fmech.2024.1369876
Adel Alblawi
In this article, an industrial gas turbine engine with a single spool (single spool 9EA-GT) is discussed, and a thermodynamic model for computing steady-state performance is presented. In addition, a novel component map production method for investigating a gas turbine engine (GTE) is developed for a different compressor and turbine by downloading from the GasTurb 12 tool and scaling to the compressor and turbine’s design points. A system of controlling engine flow capacitance by changing inlet guide vanes (IGVs) is presented. Adjusting the controllable IGV blades can optimize all the engine units by continuously correcting the compressor features map. The airflow via the compressor, which in turn controls the airflow throughout the entire system, is managed by IGVs. The computations for steady-state performance involve two models: steady-state behavior at engine startup (from 65% to 100% speed, without load) and steady-state behavior while loading (continuous speed of 100%). In this model, the challenges brought by the lack of understanding of stage-by-stage performance are resolved by building artificial machine maps using suitable scaling methods to generalized maps derived from the previous research and validating them with experimental observations from real power plants. The engine performance simulation utilizing the maps is carried out using MATLAB. Assessment results are found to be in good agreement with the actual performance data. During a steady start, the control system used in this study decreased the fuel consumption, exhaust gas mass flow rate, and compressor-driven power for the GTE by 9.5%, 19.3%, and 37.5%, respectively, and those variables decreased by 1%, 12.2%, and 19.7%, respectively, when loading the engine.
{"title":"Model-based performance study of an industrial single spool gas turbine 9EA-GT by changing the inlet guide vane angle and modifying the compressor map","authors":"Adel Alblawi","doi":"10.3389/fmech.2024.1369876","DOIUrl":"https://doi.org/10.3389/fmech.2024.1369876","url":null,"abstract":"In this article, an industrial gas turbine engine with a single spool (single spool 9EA-GT) is discussed, and a thermodynamic model for computing steady-state performance is presented. In addition, a novel component map production method for investigating a gas turbine engine (GTE) is developed for a different compressor and turbine by downloading from the GasTurb 12 tool and scaling to the compressor and turbine’s design points. A system of controlling engine flow capacitance by changing inlet guide vanes (IGVs) is presented. Adjusting the controllable IGV blades can optimize all the engine units by continuously correcting the compressor features map. The airflow via the compressor, which in turn controls the airflow throughout the entire system, is managed by IGVs. The computations for steady-state performance involve two models: steady-state behavior at engine startup (from 65% to 100% speed, without load) and steady-state behavior while loading (continuous speed of 100%). In this model, the challenges brought by the lack of understanding of stage-by-stage performance are resolved by building artificial machine maps using suitable scaling methods to generalized maps derived from the previous research and validating them with experimental observations from real power plants. The engine performance simulation utilizing the maps is carried out using MATLAB. Assessment results are found to be in good agreement with the actual performance data. During a steady start, the control system used in this study decreased the fuel consumption, exhaust gas mass flow rate, and compressor-driven power for the GTE by 9.5%, 19.3%, and 37.5%, respectively, and those variables decreased by 1%, 12.2%, and 19.7%, respectively, when loading the engine.","PeriodicalId":53220,"journal":{"name":"Frontiers in Mechanical Engineering","volume":null,"pages":null},"PeriodicalIF":2.3,"publicationDate":"2024-04-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140683026","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-04-18DOI: 10.3389/fmech.2024.1364394
Xiaofan Liu, Shaomeng Ren, Guili Wang, Liming Ma, Yanchao Sun
Traditional robotic arms rely on complex programming and predefined trajectories to operate, which limits their applicability. To improve the flexibility and adaptability of the robot arm, the research focuses on improving the grasping performance of the robot arm based on vision technology. Kinect technology is used to capture human arm movements, and Kalman filter is introduced to smooth image data, so as to optimize the motion recognition process. In this study, the residual network model is further improved, and ELU activation function and pre-activation mechanism are introduced to enhance the classification accuracy of gesture images. The results showed that the improved ResNet50 model achieves 95% recognition accuracy after 25 iterations of training, while the original model is 80%. The application of Kalman filter makes the motion tracking curve smoother and shows the correction effect of this method. In simulation tests, the robotic arm is able to identify different elbow bending angles with 90–96 percent accuracy, while mimicking five specific hand gestures with 96–98 percent accuracy. These data support the practicability and effectiveness of the application of vision capture technology and deep learning model in the field of intelligent control of robotic arms.
{"title":"Design and research of an automatic grasping system for a robot arm based on visual image capture technology","authors":"Xiaofan Liu, Shaomeng Ren, Guili Wang, Liming Ma, Yanchao Sun","doi":"10.3389/fmech.2024.1364394","DOIUrl":"https://doi.org/10.3389/fmech.2024.1364394","url":null,"abstract":"Traditional robotic arms rely on complex programming and predefined trajectories to operate, which limits their applicability. To improve the flexibility and adaptability of the robot arm, the research focuses on improving the grasping performance of the robot arm based on vision technology. Kinect technology is used to capture human arm movements, and Kalman filter is introduced to smooth image data, so as to optimize the motion recognition process. In this study, the residual network model is further improved, and ELU activation function and pre-activation mechanism are introduced to enhance the classification accuracy of gesture images. The results showed that the improved ResNet50 model achieves 95% recognition accuracy after 25 iterations of training, while the original model is 80%. The application of Kalman filter makes the motion tracking curve smoother and shows the correction effect of this method. In simulation tests, the robotic arm is able to identify different elbow bending angles with 90–96 percent accuracy, while mimicking five specific hand gestures with 96–98 percent accuracy. These data support the practicability and effectiveness of the application of vision capture technology and deep learning model in the field of intelligent control of robotic arms.","PeriodicalId":53220,"journal":{"name":"Frontiers in Mechanical Engineering","volume":null,"pages":null},"PeriodicalIF":2.3,"publicationDate":"2024-04-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140687123","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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