An analytical approach of heat transfer modelling with thermal stresses in circular plate by means of Gaussian heat source and stress function

In the proposed research work we have used the Gaussian circular heat source. This heat source is applied with the heat flux boundary condition along the thickness of a circular plate with a nite radius. The research work also deals with the formulation of unsteady-state heat conduction problems along with homogeneous initial and non-homogeneous boundary condition around the temperature distribution in the circular plate. The mathematical model of thermoelasticity with the determination of thermal stresses and displacement has been studied in the present work. The new analytical method, Reduced Differential Transform has been used to obtain the solution. The numerical results are shown graphically with the help of mathematical software SCILAB and results are carried out for the material copper.

An External Circular Crack in an Infinite Solid Under Axisymmetric Heat Flux Loading in the Framework of Fractional Thermoelasticity

In a real solid there are different types of defects. During sudden cooling, near cracks, there can appear high thermal stresses. In this paper, the time-fractional heat conduction equation is studied in an infinite space with an external circular crack with the interior radius R in the case of axial symmetry. The surfaces of a crack are exposed to the constant heat flux loading in a circular ring R<r<ρ. The stress intensity factor is calculated as a function of the order of time-derivative, time, and the size of a circular ring and is presented graphically.

A Refined Mathematical Model of Physical Processes in a Conductor at a High-Current Pulse Discharge

A novel mathematical model describing physical processes during the flow of an aperiodic pulse current with amplitude of 100 kA along a conductor with a circular cross-section is proposed and investigated. It is shown how a short-term electric discharge of an aperiodic shape affects the distribution of the current density in the cross-section of the conductor, causing its nonuniform heating and the appearance of significant thermal forces as well as mechanical stresses and strains. Based on the developed mathematical model, the relation-ship between electromagnetic, thermal and mechanical phenomena is shown, allowing a deeper understanding of the multiphysics processes taking place. The maximum values of the current density are calculated, which on the surface of the conductor reach values of 47 kA/mm2, while the temperature rise of a copper conductor with a diameter of 2.44 mm is no more than 80ºC at high temperature gradients, which causes the appearance of thermal stresses that have value (40–50)% of the value of the short-term strength limit of electrical copper. Utilization of this model allows to more accurately determine the required conductor cross-section based on the characteristics of electromagnetic, thermal and mechanical pro-cesses. It is shown that the simplified model (the condition for the uniform distribution of the current over the cross-section) gives significantly underestimated values of temperatures and does not take into account temperature deformations.

Analysis of the main factors affecting mass production in the plastic molding process by using the finite element method

Plastic injection molding is widely used in many industrial applications. Plastic products are mostly used as disposable parts or as portable parts for fast replacements in many devices and machines. However, mass production is always adopted as an ideal method to cover the huge demands and customers’ needs. The problems of warpage due to thermal stresses, non-uniform pressure distribution around cavities, shrinkage, sticking and overall products quality are some of the important challenges. The main objective of this work is to analyze the stress distribution around the cavities during the molding and demolding to avoid their effects on the product quality. Moreover, diagnosing the critical pressure points around and overall the cavity projection area, which is subjected to high pressure will help to determine the optimum pressure distribution and ensure filling all cavities at the same time, which is another significant objective. Computer-aided design (CAD) and CATIA V5R20 are adopted for design and modeling procedures. The computer-aided engineering (CAE) commercial software ABAQUS 6141 has been dedicated as finite element simulation packages for the analysis of this process. Simulation results show that stress distribution over the cavities depends on both pressure and temperature gradient over the contact surfaces and can be considered as the main affecting factor. The acceptable ranges of the cavity stresses were determined according to the following values: the cavity and core region temperature of 55–65 °C, filling time of 10–20 s, ejection pressure 0.85 % of injection pressure, and holding time of 10–15 s. Also, theoretical results reveal that the uniform pressure and temperature distribution can be controlled by adjusting the cavities layout, runner, and gate size. Moreover, the simulation process shows that it is possible to facilitate and identify many difficulties during the process and modify the prototype to evaluate the overall manufacturability before further investing in tooling. Furthermore, it is also concluded that tooling iterations will be minimized according to the design of the selected process

Hybrid Nanofluid-Based Thermal Fluid–Structure Interaction (FSI) Investigations for the Thermal Management System of a Computer Microprocessor

The heat extraction from and cooling of computer microprocessors are challenging tasks in the modern era. Previously, the microprocessors were usually cooled by air, but now industry is shifting towards using nanofluids, as their properties are more thermo-physically stable. The experimental and numerical studies have revealed that the rate of heat transfer depends both on the thermal characteristics of the coolant and the geometry of the heat sink. For optimized results, it is recommended to analyze the combined effect of nanofluids and the geometry of the heat sink. Mini-channel heat sinks in combination with a nanofluid offered an excellent rate of heat transfer. However, passing nanofluids continuously through the system causes various problems over time; for example, the thermal stresses on the components are increased, which may lead to wear and tear of the system. In this study, a numerical investigation of mini-channel heat sinks was conducted through thermal-FSI. A numerical model was established with airfoil and Savonius pin-fin mini channel heat sinks, and they were analyzed at different flow rates from 0.25 LPM to 0.75 LPM with an increment of 0.25 LPM with different fluids, i.e., water, Al2O3–H2O, and Fe2O3–H2O nanofluids, varying their volumetric concentration. The minimum stresses were obtained while increasing the temperature drop and decreasing the pressure drop. The thermal stresses were calculated using the thermal-FSI technique and were found to be in the threshold range, and hence the material was within the yield limit at 0.75 LPM when using the Fe2O3-H2O Nanofluid at a 0° angle using the Savonius heat sink.

Studying the causes of destruction of steam superheater tubes in boiler equipment

Results of comprehensive studies of samples of prematurely destroyed 57×4 mm steam superheaer tubes of STBA 22 steel used in a boiler unit of Singburi Sugar Co, Ltd factory (Thailand) are presented. The tubes were manufactured at Interpipe Niko Tube Ltd. (Ukraine) according to JIS G 3462 Standard (Japan). They were destroyed in a short (~240 hrs) term of operation. The cause of premature destruction of tubes of the above steel grade and size assortment in the boiler unit has been established. Based on present-day investigation methods (metallography, X-ray diffraction, etc.), it was found that the tubes were operated with violation of fuel combustion conditions and heat-carrying agent circulation. Characteristic features of operation of damaged tubes include high thermal stresses from the side of the fire-chamber and limitation (or absence) of circulation of the heat-carrying agent (blockage in bends, drum heads, etc.). During operation, the tubes were also exposed to significant thermal vibration stresses (unstable combustion conditions). Prolonged overheating occurred at temperatures above 1000 °C because of violation of circulation of heat-carrying agent and unstable combustion mode. High thermal stresses at almost complete absence of a heat-carrying agent, uneven distribution of growing heat flows caused by violation of the combustion mode in the fire-chamber contributed to accelerated degradation of structure and thermal destruction of the tube metal. In a short term of operation (~240 hours), there was a significant change in the tube size (accelerated high-temperature creep) and complete recrystallization of metal structure throughout the entire wall thickness of the damaged tubes. It has been established that the accelerated degradation of metal microstructure in the destroyed tubes was associated with both overheating of the tube wall and the as-delivered metal structure non-recommended for operation at high temperatures and pressures. It was shown that it is necessary to adjust the heat treatment conditions for these tubes at Interpipe Niko Tube Ltd. The study results have made it possible to develop recommendations for eliminating violations of operating conditions and establishing control of actual heat flows in the most thermally loaded sections of the Singburi Sugar Co. Ltd factory’s steam boiler superheater. Taking into account peculiarities of the boiler equipment and its operating conditions, it was also recommended to use a more heat-resistant and refractory steel instead of the currently used material for manufacture of the steam superheater tubes. Keywords: boiler tube, steam superheater, damage, thermal destruction, structure degradation, combustion conditions, heat carrier circulation, overheating.