Papers by Keyword: Geometry

Abstract: Bipolar plates are key components of fuel cell systems, as they significantly determine efficiency, power density, and service life. In aerospace applications, their importance is further emphasized due to the dual requirement of corrosion resistance and strict weight reduction. Titanium Grade 1 combines low density and excellent corrosion resistance. However, its industrial application is limited by restricted formability. The aim of this paper is a systematic investigation of the forming behavior of Titanium Grade 1 foil material in order to define forming limits and derive manufacturing-oriented design recommendations for bipolar plates in aviation. Procedure. Sixteen distinct geometry features were developed to represent characteristic forming conditions. In addition to cross-section variations, the flow field angle was systematically altered to assess its influence on local stress and strain distribution. Furthermore, the key process parameters forming speed, forming force, and lubricant amount were varied to evaluate their impact on the forming quality. The assessment focused on form filling and material thinning. For this purpose, metallographic cross-sections were prepared, and optical 3D measurements were conducted using a Keyence system to precisely capture local wall thickness variations. Key findings Process parameters: The forming behavior of Titanium Grade 1 is strongly influenced by the applied forming force and lubrication. Form filling becomes sufficient only above 350 MPa (3.000 kN), while the lubricant amount is decisive for achievable forming depths due to the hydrostatic oil cushion effect. In contrast, forming speed shows no significant influence. Anisotropy remains a critical factor, particularly in 0° rolling direction, where premature thinning leads to fracture. Geometry parameters: Small radii are highly critical, while feature depth leads to expectedly higher thinning. Steeper flank angles improve form filling but at the cost of increased thinning. Pitch shows limited influence, although it may become relevant at very small values. Channel design is challenging, as sharp flow field angles consistently result in severe thinning and pose difficulties in tool manufacturing.

Abstract: The research presented in this scientific paper focuses on modeling the dynamics of multicomponent systems with particles of different geometries using the GROMACS software package. Three main types of particles were analyzed in the study: spheres, ellipsoids, and plates, each of which has its own unique geometric characteristics that affect their behavior in the environment. The modeling allowed us to investigate the influence of particle shape on their diffusion, self-organization, and interaction between particles of different shapes. In particular, spherical particles, having an isotropic geometry, show the highest diffusion coefficient, since their symmetrical structure minimizes the resistance of the environment. This, in turn, makes them ideal for modeling simple interactions in liquids or colloids. Ellipsoidal particles, due to their anisotropy, have a slightly reduced diffusion coefficient, since their orientation in space affects the motion. Plates, which have a significant surface area relative to the volume, demonstrate the lowest diffusion rate, which is associated with a large interaction with the environment and the resistance created by their geometry. The results of the study also showed that the diffusion coefficient decreases with increasing particle size for all types. At the same time, spheres demonstrated the highest diffusion coefficient at the same size compared to other geometries, while plates have the lowest values ​​of this indicator. Analysis of the trajectories of particle motion in space using the GROMACS software allowed us to assess the influence of geometry on particle mobility. It was found that spheres exhibit the largest displacement amplitude, which indicates their high mobility and chaotic nature of the motion. Ellipsoids have a more stable motion with smaller displacements, which is associated with their geometric anisotropy. Plates, due to the large resistance of the environment, have the smallest displacements, which indicates limited mobility. It should be noted that the obtained research results open up opportunities for a deeper understanding of interactions in complex multicomponent systems and can be useful for further research in various fields. It is also worth noting that the comparison of different types of particles with different geometries and their influence on diffusion processes allowed us to obtain valuable information for improving models and practical applications in relevant fields of science and technology.

Abstract: Wire arc additive manufacturing (WAAM) has been established to be an efficient and cost-effective additive manufacturing technique for fabricating functional metallic parts from scratch. However, there is need to determine optimal processing condition for each material system to produce high-quality parts. In this work, a parametric study of WAAM of AISI 308LSi was performed to determine the processing condition(s) at which single tracks of high dimensional accuracy, excellent geometry, no visible crack and pore, and high hardness required for high-quality multi-track deposition can be achieved. The track geometries were investigated using a combination of optical microscopy and image processing software. The microstructure and hardness of the deposited single tracks were examined using optical microscopy and Vickers hardness tester respectively. A process map predicting the process stability of WAAM of AISI 308LSi was developed within a process window. Continuous single tracks of high dimensional accuracy were produced from a stable deposition process. The process becomes unstable whenever the wire deposition volume per unit length of track is in excess of the available heat energy per unit length of track. The wire feed rate and traverse speed significantly influence the stability and geometry of the single tracks. The processing conditions at which single tracks of low wetting angle (<90◦), high aspect ratio (>1.5), high surface quality, and high hardness (close to the as-received material) can be deposited were determined. These processing conditions were considered suitable for the fabrication, surface modification and repair of functional engineering parts made of 308LSi stainless steel.

Abstract: The quality and geometry of deposited bead depend on their input process parameters and their interaction effects in fusion welding process. Minimum dilution and maximum bead size are the most desirable property in material processing applications. The effects of process parameters on dilution and bead geometry have been analysed during material deposition by Plasma Transferred Arc Welding (PTAW) process using the response surface method. The experimental data are used for modelling using three level factorial techniques. The mathematical models have been developed for bead height, width and dilution. The accuracy of the models has been checked using the analysis of variance. The effects of process parameters on bead geometry and dilution have been investigated.

Abstract: This work aims to develop a transient three-dimensional mathematical model to predict the temperature distribution in a fixed-bed elliptical cylindrical reactor to different geometric aspect ratio (L₂/L₁=1.5, 2.0 and 3.0). The model considers variable thermo-physical properties, a flat temperature profile at the fluid inlet, as well as a variable porosity model. The governing equation is solved using the finite volume method, coupled with WUDS interpolation scheme and fully implicit method. Results of the temperature profile along the reactor are presented and discussed at different times. As results, it was found that the maximum rate of heat transfer within the reactor occurs near the minor half-axis region of the ellipse (cross-section area of the reactor) and it intensifies over time and that the dimensionless temperature profile is practically unchanged with the aspect ratio.

Abstract: Micro-extrusion process is one of the micro-forming technology for fabrication of micro-parts such as micro-gear shaft for microelectromechanical system (MEMS) and micro pins for electronic parts. This paper presents the friction models effects and geometry effects on curving tendency of micro-extrusion 6063 aluminum alloy pins. Three friction models were considered: (1) Coulomb friction, (2) plastic shear friction, and (3) combined (Coulomb & plastic shear) friction. The finite element simulation was carried out and the results showed that the combined friction model accurately predicted the micro-extrusion results. Then, four tool geometry and position effects were investigated: (1) punch shift length, (2) die angle, (3) die shift length, and (4) bearing length. The finite element simulation was carried out to determine these tool geometry and position effects on the curving tendency of micro-extruded pins. The results showed that punch shift length and die angle did not affect the curving tendency. However, die shift length caused the micro-extruded pins to curve. The increase in bearing length helped straighten the micro-extruded pins.

Abstract: The formation of the carbon microcoils could be achieved under the low temperature (550°C). Ni powders were used as the catalyst on the alumina substrate. C₂H₂ was used as a source gas and a few amount of SF₆ gas were used as an additive gas under the thermal chemical vapor deposition system. The surface morphologies of as-grown carbon materials at the low temperature (550°C) were also investigated according to the total pressure and the injection time of SF₆ flow. At 80Torr and 10min injection time of SF₆ flow, the carbon microcoils were highly developed on the entire surface of the sample. The lower or higher total pressure and the longer injection time of SF₆ flow deteriorated the formation of CMCs. The head area of the carbon microcoils was closely investigated and the growth mode for the initiation of the carbon microcoils at the low temperature was suggested.

Abstract: Friction has a significant influence on almost all metal forming processes. An in situ measurement of the friction stress within the forming process is in general difficult. Therefore, different experimental setups based on the indirect measurement of a friction dependent value are used to determine the friction conditions in laboratory experiments. For example the ring compression test and the conical tube-upsetting test are using the change of the geometrical shape of a specimen to investigate an averaged friction coefficient within the process. The essential advantages of conical tubes are the prevention of sticking friction and a homogeneous displacement and relative velocity along the contact surface depending on the friction conditions and the used cone angle. However, in both methods the development of the friction conditions during the upsetting process and the relative velocity between tool and workpiece are unknown. In this paper an extended setup of the conical tube-upsetting test is presented. The development of the specimen profile is detected by a laser sensor during the process at elevated temperatures. Experiments are conducted for different cone angles and the measured data is compared to FE-simulations. The time-dependent geometric data is used for the calculation of the relative displacement and relative velocity between tool and workpiece at the edge of the contact zone. A comparison with classical nomograms indicates a change of the friction conditions during the upsetting process. Finally, simulations are fitted to the experimental results by using a variable friction coefficient.

Abstract: In this paper, the impact of three parameters including nanoparticles geometry, particles aggregation and borehole inclination on induced formation damage from water based drilling fluids were investigated by means of experimental studies. Accordingly, we designed a dynamic filtration setup capable to rotate and change well inclination. nanobased drilling fluids consisting of spherical, cubical and tubular shapes nanoparticles as fluid loss additives were used. Mud cake quality, core permeability impairment and degree of formation damage at various well inclinations were examined. The cluster structure of aggregated particles were determined using fractal theory and applying dynamic light scattering technique. For this purpose, drilling fluids were circulated at different well inclinations and at a constant differential pressure against a synthetic core. Field emission scanning electronic microscopy images taken from mud cakes confirmed the proposed cluster structures of nanoparticles. The experimental results show that the mud cake quality and degree of damage are functions of produced structure of aggregated particles. Moreover, by increasing the well inclination, the skin factor increases. However, this trend is intensively depended on particle geometry. Real time analysis of pore throat size to particle size ratio during mud circulation shows the tendency of particles to create external/internal filter cake is mainly related to well inclination and particle shape. The results can be used to optimize the size and shape of selected macro/nanoparticles as additives in drilling fluids to reduce formation damage in directional and horizontal wells during drilling operation.

Abstract: In this paper are presented and analyzed a series of problems that are appearing during the CFRP machining. Due to their properties, the composite materials began to replace traditional materials (ferrous and non-ferrous) in a lot of industries leading out the development of new methods of machining or adaptation of the classic. Unlike traditional material, drilling in CFRP is more difficult due to inhomogeneity of the material, its high hardness but also due to lack of knowledge relating to how these materials behave. This paper investigates different types of tool wears as corner wear, welding, crater wear that are appearing in drilling operation due to the highly abrasive nature of the carbon fibers. Also, here is presented an evaluation that refers to the machined hole quality and describe defects as delamination, pull outs, fibers projections, pyrolysis and shape errors. The main goal of this paper is to verify the current status of technique in CFRP drilling in order to develop and produce a new drill geometry in a cooperation between the Technical University of Cluj-Napoca and the cutting tool company Gühring KG.