Experimental analysis of influence of double-layer bump foils on aerodynamic thrust foil bearings performance

Purpose Gas thrust foil bearings (GTFBs) are used to balance the axial load of engines. However, in some working conditions of large axial force, such as the use of single impeller air compressor, the load capacity of GTFBs is still insufficient. To solve this problem, the load capacity can be improved by increasing the stiffness of bump foil. The purpose of this paper is to explore a scheme to effectively improve the performance of thrust foil bearings. In the paper, the stiffness of bump foil is improved by increasing the thickness of bump foil and using double-layer bump foil. Design/methodology/approach The foil deformation of GTFBs supported by three different types of bump foils, the relationship between friction power consumption and external force and the difference of limited load capacity were measured by experimental method. Findings The variation of the foil deformation, bearing stiffness, friction power consumption with the external force at different speeds and limited load capacity are obtained. Based on experimental results, the selection scheme of bump foil thickness is obtained. Originality/value This paper provides a feasible method for the performance optimization of GTFBs.

Design guidelines for bump-type compliant conical foil bearing

The integral bump foil strip cannot optimize the performance for the compliant conical foil bearing (CFB) as the uneven distribution of structural stiffness. To maximize the bearing characteristics, this paper proposed different bump foil schemes. Firstly, the anisotropy of CFB was studied based on the nonlinear bump stiffness model, and the circumferentially separated foil structure was proposed. Moreover, an axially separated bump foil structure with the variable bump length was introduced to make the axial stiffness distribution more compliant with the gas pressure. In addition, the effect of foil thickness was also discussed. The results show that CFB with integral bump foil exhibits obvious anisotropy, and the suggested installation angle for largest load capacity and best dynamic stability are in the opposite position. Fortunately, a circumferential separated bump foil can improve this defect. The characteristics of CFB with axial separated foil structure can be improved significantly, especially for that with more strips and the variable bump half-length design. The suitable bump and top foil thickness should be set considering the improved supporting performance and proper flexibility. The results can give some guidelines for the design of CFB.

Electron Microscopy of Bubbles and Dislocations in Helium Implanted Metals

<p>The theoretical contrast in transmission electron microscope of a superlattice of helium gas bubbles in copper is computed using the two-beam and many-beam dynamical theories of electron diffraction with the aim the aim of measuring the density and size of dislocation loops associated with the bubble array. A wide range of parameters (foil thickness, diffraction vector, excitation error, defocus, and depth, radius, and strain-field of the bubble) is considered to considered to construct a library of theoretical images and intensity profiles for a single, isolated bubble. Various criteria are applied to obtain a measurement of the bubble radius from the simulations but the results are inaccurate because of the sensitive dependence of the intensity profile on the imaging parameters. A better measurement is profiles from a single stack of bubbles are modeled and electron diffraction from superlattices simulated. The results obtained suggest that the bubble ordering is of limited extent. A library is made of the theoretical contrast when imaging a system of dislocation loops punched out along the <110> directions by the growth of gas bubbles ordered on a superlattice aligned with the host fcc matrix. These image simulations use the displacement fields surrounding loops and bubbles predicted by isotropic elasticity theory. For a variety of structures involving loops and bubbles, the following imaging parameters were investigated: beam direction, foil normal, diffracting vector, excitation error, number of beams, and defocus, These simulations indicate that it should be possible to image the small dislocations at high density thought to be present in the bubble lattice, provided well focused micrographs taken under strong two-beam conditions can be obtained. In Practice it proved difficult to tilt specimens containing superlattices to strong two-beam conditions because of the deterioration in crystallinity resulting from the implantation. However, the lower concentrations by low dose implantations.</p>

Electron Microscopy of Bubbles and Dislocations in Helium Implanted Metals

<p>The theoretical contrast in transmission electron microscope of a superlattice of helium gas bubbles in copper is computed using the two-beam and many-beam dynamical theories of electron diffraction with the aim the aim of measuring the density and size of dislocation loops associated with the bubble array. A wide range of parameters (foil thickness, diffraction vector, excitation error, defocus, and depth, radius, and strain-field of the bubble) is considered to considered to construct a library of theoretical images and intensity profiles for a single, isolated bubble. Various criteria are applied to obtain a measurement of the bubble radius from the simulations but the results are inaccurate because of the sensitive dependence of the intensity profile on the imaging parameters. A better measurement is profiles from a single stack of bubbles are modeled and electron diffraction from superlattices simulated. The results obtained suggest that the bubble ordering is of limited extent. A library is made of the theoretical contrast when imaging a system of dislocation loops punched out along the <110> directions by the growth of gas bubbles ordered on a superlattice aligned with the host fcc matrix. These image simulations use the displacement fields surrounding loops and bubbles predicted by isotropic elasticity theory. For a variety of structures involving loops and bubbles, the following imaging parameters were investigated: beam direction, foil normal, diffracting vector, excitation error, number of beams, and defocus, These simulations indicate that it should be possible to image the small dislocations at high density thought to be present in the bubble lattice, provided well focused micrographs taken under strong two-beam conditions can be obtained. In Practice it proved difficult to tilt specimens containing superlattices to strong two-beam conditions because of the deterioration in crystallinity resulting from the implantation. However, the lower concentrations by low dose implantations.</p>

Minimization of the Lifecycle Cost of a Rotary Heat Exchanger Used in Building Ventilation Systems in Cold Climates

This article presents an analysis of rotary heat exchangers (RHE) used as heat recovery units in building ventilation systems in cold climates. Usually, heat exchangers with the highest heat transfer efficiency are the preferable option for this purpose. However, such exchangers usually have the highest media pressure drop, thus requiring the highest amount of energy for media transportation. In this study, the problem is solved by analysing the lifecycle cost (LCC) of the RHE including both the recovered heat and the electricity consumed in the fans of the air handling unit (AHU). The purpose of the investigation was to determine the optimal set of geometrical characteristics such as the exchanger’s length, foil thickness, the height and width of the air channel. Two hundred and seventy different combinations were examined using analytical dependencies and ANSYS simulations. The results are compared with experimental data obtained earlier at the KOMFOVENT laboratory. The results show that the best overall energy efficiency is obtained in heat exchangers that do not offer the best heat recovery efficiency, and LCC differences in the same climatic and economic conditions can go as high as 31 %, mainly due to the geometrical parameters of the heat exchanger.

Investigation on Hydrodynamic Performance of Flapping Foil Interacting with Oncoming Von Kármán Wake of a D-Section Cylinder

Flapping foils are studied to achieve an efficient propeller. The performance of the flapping foil is influenced by many factors such as oncoming vortices, heaving amplitude, and geometrical parameters. In this paper, investigations are performed on flapping foils to assess its performance in the wake of a D-section cylinder located half a diameter in front of the foil. The effects of heaving amplitude and foil thickness are examined. The results indicate that oncoming vortices facilitate the flapping motion. Although the thrust increases with the increasing heaving amplitude, the propelling efficiency decreases with it. Moreover, increasing thickness results in higher efficiency. The highest propelling efficiency is achieved when the heaving amplitude equals ten percent of the chord length with a symmetric foil type of NACA0050 foil. When the heaving amplitude is small, the influence of the thickness tends to be more remarkable. The propelling efficiency exceeds 100% and the heaving amplitude is 10% of the chord length when the commonly used equation is adopted. This result demonstrates that the flapping motion extracts some energy from the oncoming vortices. Based on the numerical results, a new parameter, the energy transforming ratio (RET), is applied to explicate the energy transforming procedure. The RET represents that the flapping foil is driven by the engine or both the engines and the oncoming vortices with the range of RET being (0, Infini) and (−1, 0), respectively. With what has been discussed in this paper, the oncoming wake of the D-section cylinder benefits the flapping motion which indicates that the macro underwater vehicle performs better following a bluff body.

Optimisation of micro W-bending process parameters using I-optimal design-based response surface methodology

There is an increasingly recognised requirement for high dimensional accuracy in micro-bent parts. Springback has an important influence on dimensional accuracy and it is significantly influenced by various process parameters. In order to optimise process parameters and improve dimensional accuracy, an approach to quantify the influence of these parameters is proposed in this study. Experiments were conducted on a micro W-bending process by using an I-optimal design method, breaking through the limitations of the traditional methods of design of experiment (DOE). The mathematical model was established by response surface methodology (RSM). Statistical analysis indicated that the developed model was adequate to describe the relationship between process parameters and springback. It was also revealed that the foil thickness was the most significant parameter affecting the springback. Moreover, the foil thickness and grain size not only affected the dimensional accuracy, but also had noteworthy influence on the springback behaviour in the micro W-bending process. By applying the proposed model, the optimum process parameters to minimize springback and improve the dimensional accuracy were obtained. It is evident from this study that the I-optimal design-based RSM is a promising method for parameter optimisation and dimensional accuracy improvement in the micro-bending process.

Warpage modeling and characterization of intelligent power modules (IPMs)

Intelligent power modules (IPMs) are widely used in the electric vehicle (and hybrid electric vehicle industry nowadays due to their high power density and ability to integrate multiple components within a single package. However, the reliability of IPMs is severely degraded by the substrate warpage effect produced during the packaging process. This study therefore develops a computational model to analyze the warpage of the IPM assembly at various stages of the packaging process. The validity of the simulation model is confirmed by comparing the numerical results for the warpage of the direct plated copper substrate with the experimental observations. Taguchi experiments are then performed to examine the effects of eight control factors on the IPM package warpage following the post-mold cure (PMC) process, namely (1) the dam bar layout, (2) the epoxy molding compound (EMC) thickness, (3) the lead frame thickness, (4) the ceramic thickness, (5) the bottom layer Cu foil thickness, (6) the top layer Cu foil thickness, (7) the ceramic material type and (8) the EMC material type. Finally, the Taguchi analysis results are used to determine the optimal packaging design that minimizes the warpage of the post-PMC package.

Analytical Model for Springback Prediction of CuZn20 Foil Considering Size Effects: Weakening versus Strengthening

The prediction of springback angle for ultra-thin metallic sheets becomes extremely difficult with the existence of size effects. In this study, size effects on the springback behavior of CuZn20 foils are investigated by experiments and analytical methods. The experimental results reveal that the springback angle first decreases gradually and then increases markedly with the decrease of foil thickness, which cannot be analyzed by current theoretical models. Then, an analytical model based on the Taylor-based nonlocal theory of plasticity is developed, in which the drastic increases of both the proportion of surface grains and the strain gradient are taken into account. Moreover, the influence of strain gradient is modified by the grain-boundary blocking factor. The calculation results show that the springback angle of foils is determined by the intrinsic competition between the decrement angle caused by surface grains and the increment angle caused by the strain gradient. Besides, the relative error of predicted springback angle by the model is less than 15%, which means that the developed model is very useful for improving the quality of micro sheet parts with high accuracy of springback prediction.