scholarly journals Erosive investigation of various erosion models for vibro cleaner developed based on ultrasonic technique using COMSOL multiphysics

2021 ◽  
Vol 13 (2) ◽  
pp. 33-41
Author(s):  
Vipulkumar Rokad ◽  
Divyang H. Pandya
Keyword(s):  
Fluid Flow ◽  
Piezoelectric Transducer ◽  
Erosion Rate ◽  
Metal Removal ◽  
Removal Rate ◽  
Comsol Multiphysics ◽  
Critical Surface ◽  
Erosion Model ◽  
Ultrasonic Cleaning ◽  
Erosion Models

The ability of ultrasound to produce highly controlled erosion phenomenon was investigated and various erosion models have been compared by considering various parameters. In cleaning industry, Vibro Cleaner (VC) has been used to remove contaminations from the surface of metal components. This process is most preferable to out of reach or critical surface of the objects. The novelty of this research is to compare various erosion models and to identify appropriate model for ultrasonic cleaning application to get meaningful results of metal removal rate. The computational model of Vibro Cleaner has been developed using pressure acoustic transient in COMSOL Multiphysics software. Acoustic and Computational Fluid Dynamics (CFD) modules have been coupled together to investigate erosion rate. In acoustic approach, acoustic pressure and sound pressure level have been studied by means of piezoelectric transducer through tank wall transience. In CFD approach, Bubbly fluid flow has been applied to get turbulence in acoustic streaming. Also, particle tracing has been coupled to understand the particle trajectories and motion of fluid flow. Erosion terms are also introduced at a surface of metal parts which need to be clean. The Erosion rate has been evaluated by using cavitation erosion phenomenon in which cavitation bubbles strike and implode over the metal surface and clean the dirt, dust, oil and other contaminations. Various Erosion models like Finnie, E/CRC, Oka and Det Norske Veritas (DNV) have been studied and results have been compared to identify appropriate erosion model towards the ultrasonic cleaning application by considering 28 kHz frequency and PZT-4 piezoelectric transducer. Comparative study leads to conclude that the Finnie erosion model have given stringent results as compare to other erosion model.  

scholarly journals Integrated CO2-H2S corrosion-erosion modeling in gas production tubing and pipeline by considering passive layer activity

2021 ◽  
Author(s):  
Silvya Dewi Rahmawati ◽  
Ryan Kurniawan Santoso ◽  
Fadhila Tanjungsari
Keyword(s):  
Carbon Dioxide ◽  
Hydrogen Sulfide ◽  
Fluid Flow ◽  
Erosion Rate ◽  
Removal Rate ◽  
Formation Rate ◽  
Passive Layer ◽  
Gas Production ◽  
Horizontal Pipe ◽  
Complex Phenomena

AbstractCorrosion and erosion are the common pipe-integrity issues that occur when carbon dioxide, hydrogen sulfide and sand exist in the gas stream at the same time. Corrosion is developed by the reaction among carbon dioxide, hydrogen sulfide and iron, while erosion by the physical damage through flowing sand. When it comes to the prediction model which could accommodate both events, complex phenomena related to physics, chemistry and metallurgy should be put into account. In this paper, we develop a new-integrated corrosion-erosion model which can calculate the corrosion-erosion rate by considering the interactions among type of passive layer (mackinawite and siderite), formation and removal rate of passive layer, and surface reaction rate. The integrated model consists of fluid flow in pipes equation, kinetics of reaction, fundamental diffusion law, empirical erosion equation and fundamental Faraday’s law. Corrosion-erosion rate is obtained through iteration scenario after establishing pressure and temperature from fluid flow in pipes equation. Pipe dimension used in the simulation has tubing ID 2.992 in for vertical pipe and flowline ID 2.992 in for horizontal pipe. Simulations were conducted using hypothetic gas field data with variation of hydrogen sulfide and carbon dioxide composition. In constant erosion rate, when the hydrogen sulfide percentage is significantly greater than carbon dioxide, corrosion is more dominant than passive layer formation. However, when the carbon dioxide percentage is greater than that of hydrogen sulfide, the passive layer tends to form, resulting in scaling. These results can be explained by the faster formation rate of siderite than mackinawite. Finally, the proposed model can explain clearly the phenomena of corrosion-erosion and scaling by simplifying the complex phenomena occurred.

Performance Analysis on Eco-friendly Machining of Ti6Al4V using Powder Mixed with Different Dielectrics in WEDM

2020 ◽  
Vol 17 (3) ◽  
pp. 8128-8139
Author(s):  
S. Chakraborty ◽  
S. Mitra ◽  
D. Bose
Keyword(s):  
Metal Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Process Efficiency ◽  
Machining Parameters ◽  
Dielectric Fluids ◽  
High Emission ◽  
Pulse On Time ◽  
Pulse Off Time ◽  
Wedm Process

The recent scenario of modern manufacturing is tremendously improved in the sense of precision machining and abstaining from environmental pollution and hazard issues. In the present work, Ti6Al4V is machined through wire EDM (WEDM) process with powder mixed dielectric and analyzed the influence of input parameters and inherent hazard issues. WEDM has different parameters such as peak current, pulse on time, pulse off time, gap voltage, wire speed, wire tension and so on, as well as dielectrics with powder mixed. These are playing an essential role in WEDM performances to improve the process efficiency by developing the surface texture, microhardness, and metal removal rate. Even though the parameter’s influencing, the study of environmental effect in the WEDM process is very essential during the machining process due to the high emission of toxic vapour by the high discharge energy. In the present study, three different dielectric fluids were used, including deionised water, kerosene, and surfactant added deionised water and analysed the data by taking one factor at a time (OFAT) approach. From this study, it is established that dielectric types and powder significantly improve performances with proper set of machining parameters and find out the risk factor associated with the PMWEDM process.

Quantification of tool chatter and metal removal rate using wavelet denoising and statistical approach

2018 ◽  
Vol 49 (2) ◽  
pp. 62-81 ◽  
Author(s):  
Shailendra Kumar ◽  
Bhagat Singh
Keyword(s):  
Response Surface Methodology ◽  
Response Surface ◽  
Metal Removal ◽  
Removal Rate ◽  
Statistical Significance ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Metal Removal Rate ◽  
Chatter Index ◽  
Tool Chatter

Tool chatter is an unavoidable phenomenon encountered in machining processes. Acquired raw chatter signals are contaminated with various types of ambient noises. Signal processing is an efficient technique to explore chatter as it eliminates unwanted background noise present in the raw signal. In this study, experimentally recorded raw chatter signals have been denoised using wavelet transform in order to eliminate the unwanted noise inclusions. Moreover, effect of machining parameters such as depth of cut ( d), feed rate ( f) and spindle speed ( N) on chatter severity and metal removal rate has been ascertained experimentally. Furthermore, in order to quantify the chatter severity, a new parameter called chatter index has been evaluated considering aforesaid denoised signals. A set of 15 experimental runs have been performed using Box–Behnken design of experiment. These experimental observations have been used to develop mathematical models for chatter index and metal removal rate considering response surface methodology. In order to check the statistical significance of control parameters, analysis of variance has been performed. Furthermore, more experiments are conducted and these results are compared with the theoretical ones in order to validate the developed response surface methodology model.

Multiresponse Optimization of Al Alloy-SiC Composite Machining Parameters for Minimum Tool Wear and Maximum Metal Removal Rate

2013 ◽  
Vol 135 (2) ◽  
Author(s):  
Rajesh Kumar Bhushan
Keyword(s):  
Tool Wear ◽  
Metal Removal ◽  
Removal Rate ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Al Alloy ◽  
Machining Parameters ◽  
Metal Removal Rate ◽  
Nose Radius ◽  
Multiresponse Optimization

Optimization in turning means determination of the optimal set of the machining parameters to satisfy the objectives within the operational constraints. These objectives may be the minimum tool wear, the maximum metal removal rate (MRR), or any weighted combination of both. The main machining parameters which are considered as variables of the optimization are the cutting speed, feed rate, depth of cut, and nose radius. The optimum set of these four input parameters is determined for a particular job-tool combination of 7075Al alloy-15 wt. % SiC (20–40 μm) composite and tungsten carbide tool during a single-pass turning which minimizes the tool wear and maximizes the metal removal rate. The regression models, developed for the minimum tool wear and the maximum MRR were used for finding the multiresponse optimization solutions. To obtain a trade-off between the tool wear and MRR the, a method for simultaneous optimization of the multiple responses based on an overall desirability function was used. The research deals with the optimization of multiple surface roughness parameters along with MRR in search of an optimal parametric combination (favorable process environment) capable of producing desired surface quality of the turned product in a relatively lesser time (enhancement in productivity). The multi-objective optimization resulted in a cutting speed of 210 m/min, a feed of 0.16 mm/rev, a depth of cut of 0.42 mm, and a nose radius of 0.40 mm. These machining conditions are expected to respond with the minimum tool wear and maximum the MRR, which correspond to a satisfactory overall desirability.

Swirling Fluidized Bed Polishing: A New Non-Conventional Method of Surface Modification

2015 ◽  
Vol 813-814 ◽  
pp. 634-640
Author(s):  
N.K. Francis ◽  
K.G. Viswanadhan ◽  
M.M. Paulose
Keyword(s):  
Surface Modification ◽  
Fluidized Bed ◽  
Metal Removal ◽  
Complex Geometry ◽  
Removal Rate ◽  
Abrasive Particle ◽  
Surface Finishing ◽  
Polished Surface ◽  
Work Piece ◽  
Machining Accuracy

Swirling Fluidized Bed Polishing (SFBP) is a non–traditional alternative abrasive flow surface finishing form of Fluidized Bed Machining (FBM) in which the former has special features to overcome certain significant limitations of the latter, namely the variation of the surface roughness vertically along the component surface and the screening effect owing to the complex contours in the work piece geometry. Owing to its ability to perform machining and generate polished surface from a roughness value of Ra 1.2μ to 0.2 μ within 8 hours of processing, this new method offers greater scope in the surface modification of rough machined surfaces with complex geometry such as component with ducts and grooves. This research focus on investigating the effect of abrasive particle concentration on metal removal rate per unit area of the specimen surface. 3D surface morphology analysis investigates the quality of the polished surface and the study of circumferential uniformity and machining accuracy analysis on a complex-contoured component further investigate its scope and relevance in industrial applications.

An Improved Computational Fluid Dynamics (CFD) Model for Erosion Prediction in Oil and Gas Industry Applications

2014 ◽  
Author(s):  
Deval Pandya ◽  
Brian Dennis ◽  
Ronnie Russell
Keyword(s):  
Fluid Dynamics ◽  
Computational Fluid Dynamics ◽  
Surface Velocity ◽  
Particle Model ◽  
Model Parameters ◽  
Cfd Model ◽  
Erosion Model ◽  
Erosion Prediction ◽  
Erosion Models ◽  
Computational Fluid Dynamics Cfd

In recent years, the study of flow-induced erosion phenomena has gained interest as erosion has a direct influence on the life, reliability and safety of equipment. Particularly significant erosion can occur inside the drilling tool components caused by the low particle loading (<10%) in the drilling fluid. Due to the difficulty and cost of conducting experiments, significant efforts have been invested in numerical predictive tools to understand and mitigate erosion within drilling tools. Computational fluid dynamics (CFD) is becoming a powerful tool to predict complex flow-erosion and a cost-effective method to re-design drilling equipment for mitigating erosion. Existing CFD-based erosion models predict erosion regions fairly accurately, but these models have poor reliability when it comes to quantitative predictions. In many cases, the error can be greater than an order of magnitude. The present study focuses on development of an improved CFD-erosion model for predicting the qualitative as well as the quantitative aspects of erosion. A finite-volume based CFD-erosion model was developed using a commercially available CFD code. The CFD model involves fluid flow and turbulence modeling, particle tracking, and application of existing empirical erosion models. All parameters like surface velocity, particle concentration, particle volume fraction, etc., used in empirical erosion equations are obtained through CFD analysis. CFD modeling parameters like numerical schemes, turbulence models, near-wall treatments, grid strategy and discrete particle model parameters were investigated in detail to develop guidelines for erosion prediction. As part of this effort, the effect of computed results showed good qualitative and quantitative agreement for the benchmark case of flow through an elbow at different flow rates and particle sizes. This paper proposes a new/modified erosion model. The combination of an improved CFD methodology and a new erosion model provides a novel computational approach that accurately predicts the location and magnitude of erosion. Reliable predictive methodology can help improve designs of downhole equipment to mitigate erosion risk as well as provide guidance on repair and maintenance intervals. This will eventually lead to improvement in the reliability and safety of downhole tool operation.

Planarization of Copper Damascene Interconnects by Spin-Etch Process: A Chemical Approach

2000 ◽  
Vol 612 ◽  
Author(s):  
Shyama P. Mukherjee ◽  
Joseph A. Levert ◽  
Donald S. Debear
Keyword(s):  
Fluid Flow ◽  
Process Parameters ◽  
Removal Rate ◽  
Normal Load ◽  
Chemical Mechanical Planarization ◽  
Copper Interconnects ◽  
Primary Process ◽  
Technical Parameters ◽  
Controllable Process ◽  
Damascene Interconnects

ABSTRACTThe present work describes the process principles of “Spin-Etch Planarization” (SEP), an emerging method of planarization of dual damascene copper interconnects. The process involves a uniform removal of copper and the planarization of surface topography of copper interconnects by dispensing abrasive free etchants to a rotating wafer. The primary process parameters comprise of (a) Physics and chemistry of etchants, and (b) Nature of fluid flow on a spinning wafer. It is evident, that unlike conventional chemical-mechanical planarization, which has a large number of variables due to the presence of pads, normal load, and abrasives, SEP has a smaller number of process parameters and most of them are primary in nature. Based on our preliminary works, we have presented the basic technical parameters that contribute to the process and satisfy the basic requirements of planarization such as (a) Uniformity of removal (b) Removal rate (c) Degree of Planarization (d) Selectivity. The anticipated advantages and some inherent limitations are discussed in the context of process principles. We believe that when fully developed, SEP will be a simple, predictable and controllable process.

scholarly journals Multi response Particle Swarm Optimization of Wire Electro Discharge Machining parameters of Nitinol alloys

2020 ◽  
Author(s):  
Mohammed Yunus ◽  
Mohammad S. Alsoufi
Keyword(s):  
Particle Swarm Optimization ◽  
Metal Removal ◽  
Removal Rate ◽  
Particle Swarm ◽  
Optimization Method ◽  
Machining Parameters ◽  
Swarm Optimization ◽  
Electro Discharge Machining ◽  
Process Factors ◽  
Wedm Process

Abstract The conventional process of Machining of Nitinol alloy leads to extensive wear on the tool and deprived surface quality. Wire electro discharge machining (WEDM) is widely accepted for machining this alloy involving various input factors, namely, P, (pulse-on-duration), Q, (pulse-off-duration), C, (maximum-current), and V, (voltage). The factor’s effect on MRR (metal removal rate) and SR (surface roughness) responses and multi-response optimization of the WEDM process by employing PSO (particle swarm optimization) method are studied. The relationship model between factors and response characteristics were generated by ANOVA and optimized by response surface methodology has shown more significant factors (A and C). Though the effect of WEDM process factors on SR and MRR are contradictory when studied individually. MRPSO method was employed to get the best optimum condition for minimizing SR and maximizing MRR. MRPSO results improved the responses for vast combination of optimal setting of factors to meet the product requirements.

Steel Wire Grinding Testing Based on New Type Abrasive Belt Grinding Machine

2012 ◽  
Vol 602-604 ◽  
pp. 2273-2278
Author(s):  
Ping Zhang ◽  
Jia Chun Li
Keyword(s):  
Metal Removal ◽  
Removal Rate ◽  
Steel Wire ◽  
Research Work ◽  
Wire Drawing ◽  
Belt Grinding ◽  
Abrasive Belt ◽  
New Type ◽  
Working Principle ◽  
Grinding Machine

As a new process, the abrasive belt grinding plays an increasingly important role in the field of machining. It meets a variety of processing requirements. The concept of abrasive belt grinding and its working principle were introduced, and a new type of abrasive belt grinding equipment for removing the rust on steel wire surface was designed. Some key experiments for testing grinding force，the metal removal rate，belt wear rate、grinding ratio，grinding depth and wire speed were studied. The research work provides rational parameters for the pretreatment of rust removal in metal wire drawing processing.

Optimization of MRR and Surface Roughness of AlMg3 (AA5754) Alloy in CNC Lathe Machine by Using Taguchi Method

2018 ◽  
Vol 877 ◽  
pp. 110-117 ◽  
Author(s):  
Poornesh Kumar Chaturvedi ◽  
Harendra Kumar Narang ◽  
Atul Kumar Sahu
Keyword(s):  
Surface Roughness ◽  
Taguchi Method ◽  
Metal Removal ◽  
Removal Rate ◽  
Surface Condition ◽  
Point Of View ◽  
Depth Of Cut ◽  
Metal Removal Rate ◽  
Cnc Lathe ◽  
Lathe Machine

Quality of the product is the major concern in manufacturing industries from customers as well as producers point of view. There are number of factors in the product such as surface condition, height, weight, length, width etc., which may be consider for the measurement of the quality. Surface roughness and Metal Removal Rate (MRR) are the two main outcomes on which numerous researchers have applied different approaches for several years to get optimum results. In this study, Taguchi Method is applied for getting optimum parameters settings for Surface roughness and Metal Removal Rate (MRR) in case of turning AlMg3 (AA5754) in CNC Lathe machine, which is an aluminum alloy having diameter 20 mm and length 100 mm. The three parameters i.e. spindle speed, feed rate and depth of cut with 3 levels are taken as the process variables and the working ranges of these parameters for conducting experiments are selected based on Taguchi’s L9 Orthogonal Array (OA) design. To analyze the significant process parameters; main effect plots for data means and for S/N ratio are generated using Minitab statistical software.

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