THERMAL DRILLING OPTIMIZATION IN MULTI HOLE PLATES

The article presents the results of simulation of thermal deformations by the finite element method for round multi-hole plates used in heat exchangers. The heat generated when drilling holes causes thermal deformation of these objects, which contributes to errors in the location of the holes. Obtained results of simulation were compared for different drilling strategies (the studies considered 24 different strategies). It was found that the maximum drilling temperatures according to different strategies may differ by up to 100%. Similar conclusions can be drawn for thermal deformations. The general conclusion that results from the conducted research indicates the need to choose a strategy that ensures the symmetry of the drilled holes in relation to the axis of symmetry of the object. Then, both thermal deformation and maximum temperature are the smallest. The thus identified thermal deformations can form the basis for the correction of the coordinates of the holes on a CNC multi-spindle drilling machine.

Thermal Deformations of Thermoplast during 3D Printing: Warping in the Case of ABS

This research focuses on thermal deformations of thermoplast during three-dimensional printing. A filament acrylonitrile butadiene styrene was used, and the main focus was put on warping. Twenty-seven cuboids divided in six categories by their length, height, surface area, color, nozzle temperature and bed temperature were printed by Fused Filament Fabrication 3D printer. The whole process was captured by a thermal camera and the movies were used to analyze the temperature distribution during printing. All printouts were measured and scanned with a 3D scanner in order to highlight any abbreviations from the original digital models. The obtained results were used to formulate some general conclusions on the influence of selected parameters on the warping process. Based on the outcomes of the study, a set of guidelines on how to minimalize warping was proposed.

Thermal Deformations of Crystal Structures in the L-Aspartic Acid/L-Glutamic Acid System and DL-Aspartic Acid

The method of temperature-resolved powder X-ray diffraction (TRPXRD) was used to determine the elevated temperature behavior of L-aspartic acid (L-asp), DL-aspartic acid (DL-asp), L-glutamic acid (L-glu), and an L-asp0.25,L-glu0.75 solid solution. These amino acids were not found to undergo any solid-phase (polymorph) transformations. When heated, they all experienced only thermal deformations. The corresponding parameters of the monoclinic cells of L-asp and DL-asp, and the orthorhombic cells of L-glu and L-asp0.25,L-glu0.75, were calculated for the entire range of studied temperatures (up to 220 °C). The data obtained were used to calculate the parameters of the thermal deformation tensors, and to plot the figures of their thermal expansion coefficients. A correlation between the maximum and minimum values of thermal expansion coefficients and the length, type, direction, and number of hydrogen bonds in the crystal structures of the investigated amino acids was established. The observed negative thermal expansion (contraction) of crystal structures of L-asp and DL-asp along the ac plane can be explained as a result of shear deformations occurring in monoclinic crystals with a non-fixed angle β. The studies were related to the presence of amino acids in various natural and technological processes occurring at different temperatures.

COMPARISON OF METHODS FOR CONTROLLED THERMAL DEFORMATIONS IN MACHINE TOOLS

Progress in improving the accuracy of metal-cutting machines is inextricably linked and driven by deeper knowledge gained through the study of thermal processes and effects occurring in machines, which can be used to manage them. This led to the dominance of temperature errors in the balance of machine accuracy, the share of which changed from 20-30% to 70% during the period from 1950 to 2020, which is determined by the absolute value of the achievable machine accuracy. Types and forms of compensation methods were formed (1990-2020), which were based on the use of linear and nonlinear regression or correlation methods. Performing experiments can establish the functional relationship between the measured temperature in the machine nodes and the amount of displacement. With good repeatability and stable reproducibility of the result, an equation expresses this functional relationship. Applying this equation to a program, a control device compensates the thermal deformations. However, in all cases, it is necessary to determine the number and location of temperature measurements on the machine, determining the compensation accuracy. The proposed sensorless model is based on a thermal behavior model and does not require temperature measurements. A method is presented and justified for estimating the number of temperature measurement locations based on thermophysical analysis by applying the finite element method in comparison with the analytical method in order to achieve the required compensation accuracy. For several machine tool types, a comparison is given regarding the control method of the TCP spindle displacement without sensors and with temperature sensors. The limits of their rational use are presented.

Influence of Thermoelastic Phenomena on the Energy Conservation in Non-Contacting Face Seals

The purpose of this study was to develop a mathematical model for non-contacting face seals to analyze how their performance is affected by thermoelastic phenomena. The model was used to solve thermal conductivity and thermoelasticity problems. The primary goal was to calculate the values of thermal deformations of the sealing rings in a non-contacting face seal with a flexibly mounted rotor (FMR) for a turbomachine. The model assumes the conversion of mechanical energy into heat in the fluid film. The heat flux generated in the fluid film is transferred first to the sealing rings and then to the fluid surrounding them. Asymmetric distribution of temperature within the sealing rings leads to the occurrence of thermal stresses and, consequently, a change in the geometry of the rings. The model is solved analytically. The distributions of temperature fields for the sealing rings in the cross-sections are calculated using the Fourier-Bessel series as a superficial function of two variables (r,z). The thermoelasticity problems described by the Navier equations are solved by applying the Boussinesq harmonic functions and Goodier’s thermoelastic displacement potential function. The proposed method involves solving various theoretical and practical problems of thermoelasticity in FMR-type non-contacting face seals. The solution of the mathematical model was made use of analytical methods, and the most important obtained results are presented in graphical form, such as the temperature distributions and axial thermal distortions in cross-sections of the rings. The calculated thermal deformations of the sealing rings are used to determine the most important seal performance parameters such as the leakage rate and power loss. The article also presents a multi-criteria analysis of seal rings materials and geometry, which makes it easier to choose the type of materials used for the sliding rings.

Influence of Thermoelastic Phenomena on the Energy Conservation in Non-contacting Face Seals

The purpose of this study was to develop a mathematical model for non-contacting face seals to analyze how their performance is affected by thermoelastic phenomena. The model was used to solve thermal conductivity and thermoelasticity problems. The primary goal was to calculate the values of thermal deformations of the sealing rings in a non-contacting face seal with a flexibly mounted rotor (FMR) for a turbomachine. The model assumes conversion of mechanical energy into heat in the fluid film. The heat flux generated in the fluid film is transferred first to the sealing rings and then to the fluid surrounding them. An asymmetric distribution of temperature within the sealing rings leads to the occurrence of thermal stresses and, consequently, a change in the rings geometry. The model is solved analytically. The distributions of temperature fields for the sealing rings in the cross-sections are calculated using the Fourier-Bessel series as a superficial function of two variables (r,z). The thermoelasticity problems described by the Navier equations are solved by applying the Boussinesq harmonic functions and Goodier’s thermoelastic displacement potential function. The proposed method involves solving various theoretical and practical problems of thermoelasticity in FMR-type non-contacting face seals. The calculated thermal deformations of the sealing rings are used to determine the most important seal performance parameters such as the leakage rate and power loss.