Kaiserslautern - Fachbereich Maschinenbau und Verfahrenstechnik
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Examination of laminar Couette flow with obstacles by a low-cost particle image velocimetry setup
(2021)
For many technical applications, a detailed analysis of the fluid mechanical properties is necessary, for which computational fluid dynamics (CFD) simulations are used. However, even though flow simulations are becoming faster and more accurate, validation through experimentation is essential. One way of validation is to use Particle Image Velocimetry (PIV), an imaging technique that can visualize the flow field and measure flow velocities. Since the measuring equipment of commercial systems is very expensive, we propose a low-cost PIV setup that is also affordable for small scientific institutions. In addition to the quality of the acquired images, the reliability and comparability between experiment and simulation are also important issues. Therefore, in this work, we compare the image acquisition quality of the proposed low-cost PIV system with two- and three-dimensional CFD simulations for a laminar Couette flow and a laminar flow around square and hexagonal obstacles with very good agreement. In addition, we analyzed the transferability of 2D and 3D CFD simulations with experiments by measuring the velocity field and found that experimentally determined flow velocities often cannot be used to validate idealized (2D) simulations due to the spatial flow that occurs. However, if the non-ideal conditions of the experiment are considered in the (3D) simulation, a good comparability is given and an experimental validation is possible, for which the presented low-cost PIV system is well suitable.
In situ condition monitoring of rotary shaft seals could significantly improve the reliability of future seals in numerous applications. A superficial application of strain gauges capturing the state of deformation could offer a cost-effective retrofit solution for indirect measurements of central operational parameters. Within a simulative investigation of the sealing system, possible sensor positions for determination of the preload as well as the friction torque prevailing in the sealing contact are therefore identified as two parameters directly related to the operating condition. Further investigations of the potential sensor signal with focus on its time-dependent behavior prove the theoretical feasibility of the measurement concepts developed and provide promising prospects for an initial technical implementation.
A novel core–shell species for the adsorption-based separation of carbon dioxide (CO2) from methane (CH4) is introduced by hydrothermal synthesis of Ni-MOF-74 on mesoporous spherical Al2O3 carrier substrate. The material was characterized and the shell thickness determined by means of optical and scanning electron microscopy as well as volumetric adsorption and fluid displacement experiments. Kinetic experiments with Ni-MOF-74@Al2O3 core–shell composites carried out at 303.15 K and at pressures up to 10 bar expose remarkably dominating uptake rates for CO2 over CH4. In the contrary Ni-MOF-74@Al2O3 appears to be unselective according to equilibrium data at the same conditions. Dynamic breakthrough experiments of binary CH4/CO2-mixtures (at 303.15 K and 5 bar) prove the prevailing effect of adsorption kinetics and the storage function of the mesoporous core. This statement is supported by a considerable boost in CO2-selectivity and capacity compared to adsorption equilibria measured on pure Ni-MOF-74 by the factor of 55.02 and up to 2.42, respectively.
Surface wetting can be simulated using a phase field approach which describes the continuous liquid-gas transition with the help of an order parameter. In this publication, wetting of non-planar surfaces is investigated based on a phase field model by Diewald et al. [1, 2]. Different scenarios of droplets on rough surfaces are simulated. The static equilibrium for those scenarios is calculated using an Allen-Cahn evolution equation. The influence of the surface morphology on the resulting contact angle is investigated while the width of the phase transition from liquid to gas is varied as a model parameter.
Print path-dependent contact temperature dependency for 3D printing using fused filament fabrication
(2022)
This paper focuses on the effects of different time spans and thus different contact temperatures when a molten strand contacts an adjacent already solidified strand in a plane during 3D printing with fused filament fabrication. For this purpose, both the manufacturing parameters and the geometry of the component are systematically varied and the effect on morphology and mechanical properties is investigated. The results clearly show that even with identical printing parameters, the transitions between the individual layers are much more visible with long time spans until fusion and lead to low mechanical properties. In contrast, short spans lead to hardly visible welds and high mechanical properties. Transferring the findings to different component sizes ultimately verifies that the average temperature at the time of contact between the already solidified and the currently deposited strand is decisive for component quality. In order to generate high component qualities, this finding must therefore be taken into account in the future in the path generation strategy, i.e., in so-called slicing.
Methods for predicting Henry's law constants Hij are important as experimental data are scarce. We introduce a new machine learning approach for such predictions: matrix completion methods (MCMs) and demonstrate its applicability using a data base that contains experimental Hij values for 101 solutes i and 247 solvents j at 298 K. Data on Hij are only available for 2661 systems i + j. These Hij are stored in a 101 × 247 matrix; the task of the MCM is to predict the missing entries. First, an entirely data-driven MCM is presented. Its predictive performance, evaluated using leave-one-out analysis, is similar to that of the Predictive Soave-Redlich-Kwong equation-of-state (PSRK-EoS), which, however, cannot be applied to all studied systems. Furthermore, a hybrid of MCM and PSRK-EoS is developed in a Bayesian framework, which yields an unprecedented performance for the prediction of Hij of the studied data set.
In selective laser melting (SLM), a powdered material is locally melted by a laser and, after cooling, forms a coherent solid structure that enables the production of complex geometries with various materials. The process involves extreme heating and cooling rates and, thus, large temperature gradients, which lead to anisotropic material properties on the macroscopic scale and, in the worst case, reduced mechanical properties. In order to reliably predict the final mechanical component properties, simulations can be performed at different time and length scales. Enormous computational resources are often required to perform such simulations. In order to transform these simulations into suitable surrogate models, the generated data must be compressed and evaluated in a suitable way. This paper shows first preliminary work and a possible new data description of such simulations.
In diesem Beitrag stellt sich die Nachwuchswissenschaftlerin Dr.-Ing. Dorina Strieth vom Lehrgebiet Bioverfahrenstechnik der TU Kaiserslautern vor. Neben aktuellen Forschungsarbeiten und Lehraktivität berichtet sie über die Notwendigkeit des Wissenstransfers in die Zivilgesellschaft. Fachlich berichtet sie von aktuellen Ergebnissen der intelligenten Nutzung phototropher Biofilme sowie dem Potenzial zur biotechnologischen Herstellung nachhaltiger Baumaterialien.
Model-based prediction is becoming increasingly important to meet the ever-increasing demands on manufacturing. In grinding, the prediction of the process forces and the generated surface by physical models are particularly important.Since cooling lubricants are almost always used on an industrial scale, the grinding model, developed at our institut, must be extended to include this component. Therefore, in order to implement cooling lubricants into the FEM-based model, it is first necessary to investigate the behaviors and effects of cooling lubricants in real experiments. Various influencing factors such as the scratching speed of individual abrasive grains in interaction with cooling lubricants need to be investigated. However, the existing physical grinding model is not limited exclusively to the prediction of the resulting forces. It is also supposed to be able to qualitatively predict the expected resulting surface of the workpiece. Hence, this paper will focus on the topographic characteristics that can occur in the scratch test due to different cooling lubricants and scratching speeds.Based on real experiments on a test rig for such scratch tests, it has been shown that different scratch speeds have a negligible influence on the topographical nature and expression of a scratch. In contrast, however, there is a direct influence of cooling lubricants on the topographic properties. This effect is additionally influenced by the viscosity of the cooling lubricant used.
In gravity separators, also known as settlers, two immiscible liquid phases separate due to differences in density. In extraction mixer-settler units, a dispersion needs to be separated within the separator unit. In order to overcome the hitherto purely experimental design, a knitted mesh adapted model as well as an automated test facility were developed in this work, which easily enable a scale-up to industrial units. An automation allows for a controlled investigation of knitted meshes as coalescing aids in settlers, and this was achieved via photo-optical probes with an optimized image analysis technique. It overcomes the limitations of neuronal network training based on manually annotating images using computer-generated image data. Therefore, the new methodology and setup are explained in detail, and the derivation and application of a new model to design separators with knitted meshes as coalescing aid is presented and compared to experimental results using meshes of different structures and materials. Finally, case studies and scale-up are discussed.