Energy Efficient, Highly Precise Cascade Dryness Control for Fibrous Tape by Induction-Based Surface Heating of a Rotating Steel Cylinder with Moving Inductors

Drying various materials constitutes an essential component of several industrial processes, e.g., paper production. Typically, rotating cylinders heated internally by water steam are used for drying tape-shaped material in paper-making machines. Such an approach remains very energy-consuming, while the whole process is expensive and in conflict with the global policy of reducing energy consumption in heavy industry. One promising alternative method of drying fibrous tapes is the induction heating of drying cylinders. In this paper, we propose a drying system based on a set of inductors (electromagnetic field sources) that generate energy in the mantle of the cylinder and dry the running tape. By enabling the movement of the inductors, the system provides a high level of flexibility in terms of reacting to the varying humidity of the tape. Additionally, imaging the temperature field on the cylinder surface provides a supplementary source of information, enabling the temperature profile to be controlled. Two types of humidity control systems, a one-loop feedback control and a cascade control, were designed and analyzed. Simulation analysis and experimental verification performed using a semi-industrial setup proves that using the proposed cascade control ensures more than 30% faster response of the whole dryness control system.

An experimental investigation of the effect of coating on heat transfer during quenching

The work is aimed at studying the effect of galvanic nickel coating of a stainless steel cylinder on the quenching. In order to compare the results, the polished stainless steel cylinder was used as a sample. In addition, the influence of the formation of an oxide layer on the cooling process was studied. The experiments were carried out in water and ethanol with different subcoolings. The oxidized porous nickel coating led to increasing of the transition temperature from stable film boiling to intensive boiling regime. It was especially noticeable for cooling in water at high subcooling due to the higher cooling intensity caused by vapour layer thinning.

Mathematical Modeling and Computer-Aided Simulation of the Acoustic Response for Cracked Steel Specimens

Photoacoustic imaging (PAI) is an emerging nondestructive testing technique to evaluate ever-growing steel products and structures for safety and reliability. In this study, we have analyzed steel material with inbuilt cracks using computer-aided numerical simulations, imitating the PAI methodology. Cracks are introduced in a steel cylinder along three axes at different locations, and then a finite element method simulation in Abaqus software is performed to generate an acoustic wave and read it back at sensing locations after passing through the crack. The data are observed, analyzed, and modeled using the composite sine wave data fitting modeling technique. Afterwards, the Nelder–Mead simplex method is used to optimize the parameters of the model. It is concluded that with the change in the crack location, there is a change in the model parameters such as amplitude and frequencies. Results for cracks at seven different locations along each of the three axes are added, and listed in tabular form to present an analysis and comparison of the changes in the modeled parameters with respect to these crack locations.

Influence of the Kinematic System on the Geometrical and Dimensional Accuracy of Holes in Drilling

This article attempts to show how the kinematic system affects the geometrical and dimensional accuracy of through-holes in drilling. The hole cutting tests were performed using a universal turning center. The tool was a TiAlN-coated Ø 6 mm drill bit, while the workpiece was a C45 steel cylinder with a diameter of 30 mm and a length of 30 mm. Three kinematic systems were studied. The first consisted of a fixed workpiece and a rotating and linearly moving tool. In the second, the workpiece rotated, while the tool moved linearly. The third system comprised a rotating workpiece and a rotating and linearly moving tool, but they rotated in opposite directions. The geometrical and dimensional accuracy of the hole was assessed by analyzing the cylindricity, straightness, roundness, and diameter errors. The experiment was designed using the Taguchi orthogonal array method to determine the significance of the effects of the input parameters (cutting speed, feed per revolution, and type of kinematic system) on the accuracy errors. A multifactorial statistical analysis (ANOVA) was employed for this purpose. The study revealed that all the input parameters considered had a substantial influence on the hole quality in drilling.

Effect of Axial Deformation Caused by Torsion on a Solid Steel Cylinder

Equations describing the classical theory of applied torsion and axial rotation on a solid cylindrical shaft have been modified by Shirali and Hossain (2019) to derive new theorems, which can take into consideration axial deformation of members. The modified theorems use various empirical parameters to introduce the combined effect of axial force, axial displacement and axial rotation, which is neglected in classical theorems of torsion. Multiple finite element analysis models for solid steel cylindrical members, fixed at one end and subjected to torsion at its free end, were developed to study the effects of torsional loading. The effect of axial deformation/stress developed in the cylinder is analyzed and compared with values predicted by classical and proposed modified theorems (equations). It is shown that the cylinder can shorten or elongate when subjected to torsion. The proposed theorems/equations, based on axial deformation subjected to torsion, provide more accurate predictions of shear stress and axial rotation (angle of twist).

Effect of Axial Deformation Caused by Torsion on a Solid Steel Cylinder

Equations describing the classical theory of applied torsion and axial rotation on a solid cylindrical shaft have been modified by Shirali and Hossain (2019) to derive new theorems, which can take into consideration axial deformation of members. The modified theorems use various empirical parameters to introduce the combined effect of axial force, axial displacement and axial rotation, which is neglected in classical theorems of torsion. Multiple finite element analysis models for solid steel cylindrical members, fixed at one end and subjected to torsion at its free end, were developed to study the effects of torsional loading. The effect of axial deformation/stress developed in the cylinder is analyzed and compared with values predicted by classical and proposed modified theorems (equations). It is shown that the cylinder can shorten or elongate when subjected to torsion. The proposed theorems/equations, based on axial deformation subjected to torsion, provide more accurate predictions of shear stress and axial rotation (angle of twist).