ANALYSIS OF TECHNOLOGICAL POSSIBILITIES OF TWO-CHAMBER IMPULSE DEVICES FOR SHEET STAMPING

Проведен анализ технологических возможностей двухкамерных устройств для листовой штамповки с одной и двумя камерами сгорания. В устройствах с одной камерой сгорания штамповка детали происходит в холодном состоянии заготовки под действием на нее гибкой среды за счет кинетической энергии поршня, ускоряемого продуктами сгорания газообразной топливной смеси. В устройствах с двумя камерами сгорания процесс штамповки совершается с нагревом заготовки воздействием на нее горячего газа, образованного при сгорании в верхней камере предварительно сжатой топливной смеси. При этом сжатие смеси осуществляется за счет энергии продуктов сгорания, образованных в нижней камере сгорания. Доказано, что устройства с одной камерой сгорания целесообразно использовать для штамповки из пластичных сортов сталей деталей разнообразной формы толщиной до 4 мм и из пластичных цветных сплавов толщиной до 8 мм. Устройства с двумя камерами сгорания целесообразно использовать для штамповки деталей из малопластичных сортов алюминиевых, титановых сплавов и других труднодеформируемых сплавов. Двухкамерные устройства для листовой штамповки обладают широкими технологическими возможностями и могут быть эффективно использованы в мелкосерийных производствах для штамповки деталей различной формы We carried out the analysis of technological capabilities of two-chamber devices for sheet stamping with one and two combustion chambers. In devices with one combustion chamber, the stamping process is carried out in the cold state of the workpiece by the action of an elastic medium on it, using the kinetic energy of the piston accelerated by the combustion products of the gaseous fuel mixture. In devices with two combustion chambers, the stamping process is carried out with the heating of the workpiece by the action of the hot gas formed during combustion in the upper chamber of the pre-compressed fuel mixture. In this case, the mixture is compressed due to the energy of the combustion products formed in the lower chamber. We established that devices with one combustion chamber are expedient to be used for stamping parts of various shapes with a thickness of up to 4 mm and from plastic non-ferrous alloys with a thickness of up to 8 mm from ductile steels. Devices with two combustion chambers are advisable to be used for stamping parts from low-plastic grades of aluminum, titanium alloys and other hard-to-deform alloys. Two-chamber devices for sheet stamping have wide technological capabilities and can be effectively used in small-scale production for stamping parts of various shapes

Influence of Fuel System Variations on Performance and Emission Characteristics of Combined Air-Wall Guided Mode Modified GDI engine with Alcoholic Fuels and Exhaust Gas Recirculation

GDI engines commercially existed with spray guided mode where the fuel injector placed almost vertically and sprayed fuel is occupied throughout the volume of combustion chamber. With the advanced emission norms, NOx and Soot emissions control is the major task along with lower fuel consumption. To achieve the advanced emission norms, further modifications are required before or during combustion. Combined air-wall guided mode combustion chamber modification is the advanced stage required for further improvement in mixing and superior combustion. Air-wall combined mode involved piston crown shape modification so that the modified shape should impart turbulence effects and divert the fuel/mixture flow towards the spark plug tip to initiate the combustion process. In this study, the combined air-wall guided mode gasoline direct injection engine was tested with gasoline blends using Ethanol, Methanol and N-Butanol at 20, 35 and 50% proportions under specific fixed conditions: 1500 rpm speed, 10% EGR and FIP of 150 bars with three split injections at 320˚, 220˚ and 100˚ before TDC. Tests were conducted over these gasoline blend proportions for engine performance and emission characteristics and achieved beneficial results with E20 gasoline blend over the entire applied torque values.

The Effect of Inert Fuel Compounds on Flame Characteristics

To describe the effects of inert compounds in gaseous fuel, experiments on three different process burners (staged fuel burner, staged air burner, and low-calorific burner) were carried out. The tested burners are commercially available, but they were specially designed for experimental usage. Tests were carried out in the semi-industrial burner testing facility to investigate the influence of inert gases on the flame characteristics, emissions, and heat flux to the combustion chamber wall. Natural gas was used as a reference fuel, and, during all tests, thermal power of 500 kW was maintained. To simulate the combustion of alternative fuels with lower LHV, N2 and CO2 were used as diluents. The inert gas in the hydrocarbon fuel at certain conditions can lower NOx emissions (up to 80%) and increase heat flux (up to 5%). Once incombustible compounds are present in the fuel, the higher amount of fuel flowing through nozzles affects the flow in the combustion chamber by increasing the Reynolds number. This can change the flame pattern and temperature field, and it can be both positive and negative, depending on actual conditions.

A study on the influence of ignition energy on ignition delay time and laminar burning velocity of lean methane/air mixture in a constant volume combustion chamber

This study presents the effect of ignition energy (Eig) on ignition delay time (tdelay) and uncertainty of laminar burning velocity (Su0) measurement of lean methane/air mixture in a constant volume combustion chamber. The mixture at an equivalence ratio of 0.6 is ignited using a pair of electrodes at the 2-mm spark gap. Eig is measured by integrating the product of voltage V(t) and current I(t) signals during a discharge period. The in-chamber pressure profiles are analyzed using the pressure-rise method to obtain tdelay and Su0. Su0 approximates 8.0 cm/s. Furthermore, the increasing Eig could shorten tdelay, leading to a faster combustion process. However, when Eig is greater than a critical value, called minimum reliable ignition energy (MRIE), the additional elevating Eig has the marginal effect on tdelay and Su0. The existence of MRIE supports to optimize the ignition systems and partly explains why extreme-high Eig>> MRIE has less contribution to engine performance.

Selection of the Design of a Contact Condenser of a Gas-Steam Plant with Steam Injection into the Combustion Chamber

Due to the importance of the problems of implementing energy-saving technologies in modern conditions, one of the promising areas is the use of gas turbines for combined heat and power generation. One of the areas of effective development and technical re-equipment is the widespread use of highly economical combined steam and gas plants and gas turbines. The operation of the gas turbine unit “Aquarius” SE NPCG “Zorya-Mashproekt” with the injection of steam into the combustion chamber, which operates on the advanced cycle A-STIG and has in its circuit equipment for water regeneration, condensed from a vapor-gas mixture is considered. For condensation of steam from the vapor-gas mixture, a contact condenser-gas cooler is used, which is a mixing heat exchanger of complex design. The efficiency of heat transfer is determined by the design of the nozzle, namely, the developed heat transfer surface, small hydraulic supports, high heat transfer coefficients. An important aspect is the overall dimensions, which must be within certain limits. In the work it is offered to execute a design of the condenser in the form of a packed column. Different types of nozzles are considered to choose the best option. As a result of thermal design calculation of the contact capacitor, it is proposed to use Rashiga rings (15152) as a nozzle, which provide the lowest height of the nozzle at the required diameter of the device.

Use of the Low-Potential Heat for Heating Helium in Rocket-Carrier Tank Pressurisation Systems

The energy efficiency of new technical developments is a critical issue. It should be noted that today the focus in this issue has seen a major shift to the maximum use of renewable energy sources. The purpose of this research is to reduce the weight of helium heat exchangers of the fuel tank pressurisation systems in modern rocket propulsion systems that use fuel components like liquid oxygen and kerosene-type fuel. This is the first time that the question has been raised about the possibility and advisability of increasing the temperature of helium at the heat exchanger inlet without the use of additional resources. The paper addresses the use of the waste (“low-potential”) heat and ”industrial wastes” present in propulsion systems. Basic laws of complex heat exchange and the retrospective review of applicable heat exchanger structures are applied as a research methodology. Two sources of low-potential heat are identified that have been previously used in the rocket engine building in an inconsistent and piecemeal manner to obtain and heat the pressurisation working fluid. These are the rammedair pressurisation during the motion of the rocket carrier in the atmosphere, and the tank pressurisation as a result of boiling of the top layer of oxidiser which is on the saturation line. This is the first time that the advisability has been substantiated of increasing the temperature of the working fluid at the heat exchanger inlet, first of all due to the use of the low-potential heat. This is also the first time that unemployed sources of low-potential heat and “industrial wastes” are found in modern deep throttling propulsion systems. These are the high-boiling-point fuel in the tank, behind the highpressure pump, at the exit of the combustion chamber cooling duct, and also the fuel tank structures, and the engine plume. A possibility is proved, and an advisability demonstrated of their implementation to increase the efficiency of pressurisation system heat exchangers. This is the first time that the methodology of combustion chamber cooling analysis has been proposed to be adopted for the heating of heat exchanger by the engine plume. This is the first time that a classification of waste heat sources has been developed which can be used to increase the pressurisation working fluid temperature. The identified reserves help to increase the efficiency of the helium heat exchangers of the tank pressurisation systems in the propulsion systems

Investigation of the co-firing of natural gas and RDF in a model combustion chamber**

The production and utilization of fuel derived from municipal solid waste (RDF/SFR) is an effective method for saving organic fuel and decreasing emissions of harmful substances and greenhouse gases at landfill and refuse dumps. Ukraine has a potential for the production of 1.5–2 million tons of RDF/SFR with a calorific value of 10–25 MJ/kg annually. In the case of involving these fuels to power sector, about 2500 GW-h of electricity and 4500 GW-h of heat can be produced annually. One of the promising variants to involve RDF/SFR to power sector is their combustion, including co-firing with natural gas, aimed at the production of heat and electricity, in particular, using the existing boilers of small and middle steam capacity in compliance with stringent ecological requirements (Directive 2010/75/EU etc.). For performing this investigation, we chose a GMP-16 gas-and-oil-fired burner, mounted into a cylindrical combustion chamber. The gas-and-oil-fired hot-water boilers of KVGM grade, designed for heating and hot water supply, are equipped with burners of this type. In computer modeling, we determined the influence of RDF additions on the co-firing with natural gas for a given geometry of the combustion chamber components (with a burner of 18.6 MW heat output). We obtained calculated dependences of temperatures, velocities, distributions of gas component concentrations, carbon remained in the solid phase, as well as the concentrations of nitrogen oxides and carbon monoxide over the combustion chamber. According to preliminary assessments, we established that additions of up to 20% RDF/SFR (by heat at input) in their co-firing with natural gas will not change substantially the technical and ecological parameters in operation of the combustion chamber.