Search Results (357)

This study optimized the punch-assisted demolding technique for the separation of contact lenses, incorporating finite-element analysis to evaluate the effects of punch geometry (punch material: 304L stainless steel) on the stress and strain distributions of polypropylene lens molds. The simulation results revealed that the punch surface featured a flat base with a central arc-shaped groove (groove diameter: 7 mm, depth: 0.75 mm), which exhibited optimal stress dispersion characteristics during the demolding process, effectively reducing mold deformation. Experimental validation over 100 demolding cycles confirmed that the use of the aforementioned punch resulted in the manufactured lens having high central stability and reduced van der Waals forces during demolding, allowing smoother lens release and facilitating improved demolding performance. Comprehensive evaluation based on defect inspection and centering stability indicated that a yield of 82% was achieved with the optimized punch, with this yield being 13% higher than that obtained with a flat punch lacking an arc groove (69%). These results indicate that the optimized punch design not only reduces development costs but also enhances manufacturing yield and throughput, demonstrating strong potential for application in contact lens production. Full article

This study focuses on a proposed aluminum alloy radiant panel with 60° V-shaped grooves and integrated copper tubes. A numerical model of this novel grooved phase change material (PCM)-integrated radiant panel was established via Fluent 2022 R1 software. Through numerical simulations, the complete melting and solidification processes of two PCMs (n-hexadecane and LTXC-PCM-A-18) were analyzed, and differences in their phase change heat transfer performance were compared—revealing the role of the groove structure in enhancing PCM heat transfer and the material-structure compatibility. Results indicate that the groove structure effectively enhances convective heat transfer in the PCM liquid phase. During the melting stage, LTXC-PCM-A-18 exhibited a preheating rate of 0.00125 K/s, which is 67% higher than that of n-hexadecane (0.00075 K/s); its liquid fraction growth rate (0.0002 s⁻¹) was 2.67 times that of n-hexadecane, and the melting completion time was accelerated by 20% (2000 s). During solidification, LTXC-PCM-A-18’s initial cooling rate (0.0006 K/s) was 50% higher than that of n-hexadecane (0.0004 K/s), with a liquid fraction decay rate twice that of n-hexadecane. Additionally, its solidification temperature plateau was 1 K higher, providing superior thermal output stability. These findings reflect two distinct technical strategies: “steady-state temperature control” and “dynamic regulation.” n-Hexadecane exhibits smoother melting and solidification processes, making it suitable for continuous heating applications. In contrast, LTXC-PCM-A-18 demonstrates superior thermal responsiveness and phase change efficiency, aligning with intermittent heating requirements. This study provides quantitative guidance for PCM selection in grooved radiant panels. Full article

The accurate modelling of material removal mechanisms in grinding processes requires precise constitutive equations describing dynamic material behaviour under extreme strain rates and large deformations. This study presents a novel methodology for optimising the Johnson–Cook (J–C) constitutive model parameters for micro-grinding applications, addressing the limitations of conventional mechanical testing at strain rates exceeding 10⁵ s⁻¹. The research employed single abrasive grain micro-cutting experiments using a diamond Vickers indenter on aluminium alloy 7075-T6 specimens. High-resolution topographic measurements (130 nm lateral resolution) were used to analyse the scratch geometry and lateral material displacement patterns. Ten modified J–C model variants (A1–A10) were systematically evaluated through finite element simulations, focusing on parameters governing plastic strengthening (B, n) and strain rate sensitivity (C). Quantitative non-conformity criteria assessed agreement between experimental and simulated results for cross-sectional areas and geometric shapes of material pile-ups and grooves. These criteria enable an objective evaluation by comparing the pile-up height (h), width (l), and horizontal distance to the peak (d). The results demonstrate that conventional J–C parameters from Hopkinson bar testing exhibit significant discrepancies in grinding conditions, with unrealistic stress values (17,000 MPa). The optimised model A3 (A = 473 MPa, B = 80 MPa, n = 0.5, C = 0.001) achieved superior convergence, reducing the non-conformity criteria to Σk_A = 0.46 and Σk_K = 1.16, compared to 0.88 and 1.67 for the baseline model. Strain mapping revealed deformation values from ε = 0.8 to ε = 11 in lateral pile-up regions, confirming the necessity of constitutive models describing material behaviour across wide strain ranges. The methodology successfully identified optimal parameter combinations, with convergence errors of 1–14% and 7–60% on the left and right scratch sides, respectively. The approach provides a cost-effective alternative to expensive dynamic testing methods, with applicability extending to other ductile materials in precision manufacturing. Full article

Burrs are a significant machining defect affecting the quality of precision parts, and tool eccentricity may substantially influence milling burrs. Using AISI 304 stainless steel as the workpiece material, a three-dimensional thermo-mechanical coupled model for slot milling was constructed based on an explicit dynamics model. Combining the Johnson–Cook (J-C) constitutive model with the J-C shear failure criterion, simulations were conducted to obtain burr dimensions, cutting temperature distributions, and cutting force waveforms under different tool eccentricity directions and magnitudes. Results: As the eccentricity increases, the temperature of the top burr rises, and both the width of the top burr and the thickness of the exit side burr significantly increase. Under simulated conditions, the width of the top burr in down milling side increased by up to 70%. The burr dimensions under different eccentricity directions can differ by approximately 40%. Groove milling experiments revealed similar burr shapes between experimental and simulated results. Furthermore, the simulated cutting force waveforms aligned with those in the literature, indicating the reliability of the simulation outcomes. Based on these findings, it can be concluded that tool eccentricity significantly affects the dimensions of top burrs and exit side burrs. The width of top burrs and the thickness of exit side burrs are positively correlated with the tool eccentricity distance, while exit bottom burrs remain unaffected by eccentricity. These research results provide valuable reference for burr suppression in practical machining operations. Full article

To mitigate the inadequate performance of traditional hydraulic systems, mechanical feedback-based digital hydraulic technology is applied to a 3-degree-of-freedom (3-DOF) crane. Digital hydraulic cylinders drive the pitch mechanism, and digital hydraulic motors power the rotary and winch mechanisms. By analyzing the working principles of digital hydraulic cylinders and motors, transfer functions of the 3-DOF actuators are derived. AMESim simulation models are established for each actuator, with model validity verified. Based on these models, simulation analysis of the digital hydraulic system is performed to examine key influencing factors: motor speed, motor subdivision, system flow rate, digital valve opening, and throttle groove shape. System characteristics are obtained, and corresponding optimization schemes are proposed. After optimization, the comprehensive performance of the digital hydraulic system is improved by 1.29%. This study provides theoretical support for the engineering application of digital hydraulic systems in cranes, clarifies their operational specifications and optimization pathways, and exhibits substantial engineering application value. Full article

This study provides a detailed review of the thermal and thermo-hydraulic performance of solar air heaters (SAHs) enhanced through the application of artificial roughness on the absorber plate. Various roughness geometries, such as wire ribs, V-shaped ribs, arc-shaped ribs, and rib-groove patterns, have been analysed to assess their influence on heat transfer enhancement and frictional behaviour. Findings from previous experimental and numerical studies reveal that the incorporation of artificial roughness can increase the Nusselt number by approximately 1.25 to 6.3 times and improve thermal efficiency by 20–35% when compared to smooth absorber plates. The review further highlights that the most effective performance occurs at a relative roughness height (e/D) between 0.02 and 0.05 and within a Reynolds number range of 10,000 to 18,000. Overall, the analysis confirms that artificial roughness is a simple, economical, and highly effective technique to enhance heat transfer and overall efficiency in solar air heater systems. Full article

Laser-MIG hybrid welding experiments were performed on 10 mm thick Invar36 alloy plates. The influence of three different types of welding grooves (V-shape, rectangle, and X-shape) on the microstructure and mechanical properties of the welded joints were analyzed. The results indicated that the grain growth morphologies and grain sizes varied among the grooves. The average grain size at the center of the weld seam was 177.97 μm, which was smaller than the top grain size of 317.29 μm and the bottom grain size of 233.59 μm. In V-shape and rectangle grooves, the dimensions of grain the first weld pass was obviously smaller than the top region of the second pass. Microstructural characterization and tensile test showed no vertically columnar grains along the weld centerline in rectangle grooves which significantly affected the mechanical properties of welded joints. As a result of this phenomenon, V-shape groove joints demonstrated better mechanical properties than rectangle groove joints. The highest average tensile strength for V-shape groove, X-shape groove, and rectangle groove joints were 429.0 MPa, 419.3 MPa, and 395.4 MPa, respectively. Based on the Abaqus software, three-dimensional finite element analyses of three groove types were performed to investigate the relationship between microstructure and groove geometries. It was observed that the higher KAM regions in the EBSD results correlated with the higher effective plastic deformation in the finite element analysis. Furthermore, it was inferred from the thermal cycle curves that variations in thermal cycles across different regions resulted differences in grain size and grain growth morphology. Full article

Based on the analysis of grooves of regular and partially regular microreliefs formed on flat surfaces, the relationship between the geometric parameters of the grooves of their microreliefs, which ensures their regularity, was revealed. The functionality of the existing parameter for assessing the oil capacity of the surface of the relative area of the grooves of the microrelief was analyzed. It was proved that the parameter—the relative area of the grooves of the microrelief—is insensitive to their distribution on the plane. A new graph-analytical method for determining the planar heterogeneity of the distribution of the area of the grooves of the microreliefs was developed. A numerical parameter—the coefficient of planar heterogeneity, which determines the uniformity of the distribution of the area of the grooves on the plane, was also substantiated. The effectiveness of the new approach was demonstrated and proven. Graphs of longitudinal and transverse planar heterogeneity of the main forms of the grooves of the microreliefs were constructed, which will eliminate the need to obtain complex analytical dependencies to determine the area of these grooves. By analyzing the graphs of planar heterogeneity, numerical values of the heterogeneity coefficient were determined—a parameter that characterizes the homogeneity of microrelief grooves in the axial and interaxial directions. It is proposed to search for optimal placement schemes of adjacent microrelief grooves on the plane based on the analysis of their planar heterogeneity coefficients. This will ensure an increase in the plane heterogeneity coefficient from 0.69 to 0.97 for the triangular shape of the grooves, from 0.87 to 0.83 for the sinusoidal and from 0.46 to 0.69 for the groove shape in the form of a truncated cycloid, with the same relative areas of the microrelief. Full article

Differing from traditional isobaric combustion, a pulse detonation-based ramjet (PD-Ramjet) was proposed in this study to enhance the efficiency of traditional ramjets. By using a two-dimensional numerical simulation method, the filling process and detonation initiation process of the hydrogen/air stoichiometric mixture in channels equipped with typical flameholders were studied under the inflow condition of a ramjet combustor, and the influences of the typical flameholders on the filling process and detonation initiation process were analyzed. Single cavity, sudden expansion cavity, central cavity, and V-shaped groove were chosen as typical ramjet flameholders. The simulation and analysis results indicated that the flameholders would affect the filling effect, and the blocking ratio had a great influence on the filling process. The hydrogen volume discharged from the outlet of the channel and the time for mixed gas to reach the outlet were related to the blocking ratio and the cavity aft wall inclination angle. The detonation initiation process revealed that the flameholders promoted the generation of detonation waves. Contrastingly, the detonation wave could not be initiated in the channel without flameholders despite the better filling effect. Moreover, different flameholders would change the position of high-pressure point formation and the time for generating the stable detonation wave. On the whole, the sudden expansion cavity had a lower blockage ratio and also gave consideration to the filling effect and detonation initiation characteristic, making it the most suitable flameholder structure for PD-Ramjet in this study. Full article

Hydrodynamic cavitation usually occurs in marine and ocean engineering and hydraulic systems and may lead to destructive effects such as an enhanced drag force, noise, vibration, surface damage, and reduced efficiency. Previous studies employed several passive and active control strategies to manage unstable cavitation and its adverse effects. This study reviews various passive and active control strategies for managing diverse cavitation stages, such as partial, cloud, and tip vortex. Regarding the passive methods, different control factors, including the sweep angle of the foil, roughness, bio-inspired riblets, V-shaped grooves, J grooves, obstacles, surface roughness, blunt trailing edge, slits, various vortex generators, and triangular slots, are discussed. Regarding the active methods, various injection methods including air, water, polymer, and synthetic jet and piezoelectric actuators are reviewed. It can be concluded that unstable cavitation can be controlled by both the active and passive approaches independently. However, in the severe conditions of cavitation and higher angles of attack, the passive control methods can only alleviate some re-entrant jets propagating in the downward direction, and proper control of the cavity structure cannot be achieved. In addition, active control methods mostly require supplementary energy and, consequently, lead to higher expenses. Combined passive active control technologies are suggested by the author, using the strengths of both methods to suppress cavitation and control the cavitation instability for a broad range of cavitating flows efficiently in future works. Full article

Tandem cylinders, widely used in heat exchangers, water storage units, and electronic cooling, require optimized flow and heat transfer to enhance engineering performance. However, the combined effects of various factors in tandem configurations remain insufficiently explored. This study proposes an innovative approach that integrates multiple parameters to systematically investigate the influence of surface pattern characteristics and rotational speed on the fluid dynamics and heat transfer performance of tandem cylinders. Numerical simulations are conducted to evaluate the effects of various pattern dimensions (w/D = 0.12–0.18), surface shapes (square, triangular, and dimpled grooves), rotational speeds (|Ω| ≤ 1), and frequencies (N = 2–10) on fluid flow and heat transfer efficiency at Re = 200. The study aims to establish the relationship between the complexity of the coupling effects of the considered parameters and the heat transfer behavior as well as fluid dynamic variations. The results demonstrate that, under stationary conditions, triangular grooves exhibit larger vortex structures compared to square grooves. When a positive rotation is applied, coupled with increases in w/D and N, square grooves develop a separation vortex at the front. Furthermore, the square and dimpled grooves exhibit significant phase control capabilities in the time evolution of lift and drag forces. Under conditions of w/D = 0.12 and w/D = 0.18, the C_L of the upstream cylinder decreases by 17.2% and 20.8%, respectively, compared to the standard smooth cylinder. Moreover, the drag coefficient C_D of the downstream cylinder is reduced to half of the initial value of the upstream cylinder. As the surface amplitude increases, the C_D of the smooth cylinder surpasses that of the other groove types, with an approximate increase of 8.8%. Notably, at Ω = −1, the downstream square-grooved cylinder’s C_L is approximately 12.9% lower than that of other groove types, with an additional 6.86% reduction in amplitude during counterclockwise rotation. When N increases to 10, the ${\overline{C}}_D$ of the upstream square-grooved cylinder at w/D = 0.18 decreases sharply by 20.9%. Conversely, the upstream dimpled-groove cylinder significantly enhances ${\overline{C}}_p$ at w/D = 0.14 and N = 4. However, the upstream triangular-groove cylinder achieves optimal ${\overline{C}}_p$ stability at w/D ≥ 0.16. Moreover, at w/D = 0.18 and N = 6, square grooves show the most significant enhancement in vortex mixing, with an increase of approximately 42.7%. Simultaneously, the local recirculation zones in dimpled grooves at w/D = 0.14 and N = 6 induce complex and geometry-dependent heat transfer behaviors. Under rotational conditions, triangular and dimpled grooves exhibit superior heat transfer performance at N = 6 and w/D = 0.18, with TPI values exceeding those of square grooves by 33.8% and 28.4%, respectively. A potential underlying mechanism is revealed, where groove geometry enhances vortex effects and heat transfer. Interestingly, this study proposes a correlation that reveals the relationship between the averaged Nusselt number and groove area, rotational speed, and frequency. These findings provide theoretical insights for designing high-efficiency heat exchangers and open up new avenues for optimizing the performance of fluid dynamic systems. Full article

Structured CBN (cubic boron nitride) grinding wheels usually have a specially designed texture on their surface to reduce the grinding heat and grinding force. However, most structured grinding wheels are fabricated by electroplating, brazing, sintering, and mechanical or laser removal on the surface of conventional grinding wheels, which may have problems such as complicated processes, low processing efficiency, and unstable effects. In this paper, additive manufacturing was used to fabricate a radial straight groove-structured grinding wheel. Meanwhile, a corresponding mathematical model of the grinding wheel was also established considering the shape and position of the abrasive grains. Subsequently, the ground surface morphologies of the fabricated wheel and simulated wheel under different machining parameter conditions were compared to further prove the rationality of the simulated grinding wheel. The results showed that the ground surfaces of the fabricated wheel and simulated wheel had similar morphological characteristics. The trend in the surface roughness under the different machining parameter conditions was also analyzed and showed the same variation for fabricated and simulated wheels; the error rate was confined within 8%. This paper elucidates the grinding mechanism and surface morphology formation process of a radial straight groove-structured grinding wheel fabricated by additive manufacturing. Full article

As high-speed railway systems continue to develop toward intelligent operation, axle box bearings integrated with sensors have become key components for real-time condition monitoring. However, introducing sensor-embedded slots disrupts the structural continuity and thermal conduction paths of traditional bearing rings. This results in localized stress concentrations and thermal distortion, which compromise the bearing’s overall performance and service life. This study focuses on a double-row tapered roller bearing used in axle boxes and develops a multi-physics finite element model incorporating the effects of sensor-embedded grooves, based on Hertzian contact theory and the Palmgren frictional heat model. Both contact load verification and thermo-mechanical coupling analysis were performed to evaluate the influence of two key design parameters—groove depth and arc length—on equivalent stress, temperature distribution, and thermo-mechanical coupling deformation. The results show that the embedded slot structure significantly alters the local thermodynamic response. Especially when the slot depth reaches a certain value, both stress and deformation due to thermo-mechanical effects exhibit obvious nonlinear escalation. During the design process, the length and depth of the arc-shaped embedded slot, among other parameters, should be strictly controlled. The study of the stress and temperature characteristics under the thermos-mechanical coupling effect of the axle box bearing is of crucial importance for the design of the intelligent bearing body structure and safety assessment. Full article

A systematic study was conducted on the fatigue performance of Q500qENH weathering steel welded joints under low-temperature conditions of −40 °C in this paper. Low-temperature fatigue tests were conducted on V-groove butt joints and cross-shaped welded joints and S-N curves with a 95% reliability level were obtained. A comparative analysis with the Eurocode 3 reveals that low-temperature conditions lead to a regular increase in the design fatigue strength for both types of welded joints. Fracture surface morphology was examined using scanning electron microscopy, and combined with fracture characteristic analysis, the fatigue fracture mechanisms of welded joints under low-temperature conditions were elucidated. Based on linear elastic fracture mechanics theory, a numerical simulation approach was employed to investigate the fatigue crack propagation behavior of welded joints. The results indicate that introducing an elliptical surface initial crack with a semi-major axis length of 0.4 mm in the model effectively predicts the fatigue life and crack growth patterns of both joint types. A parametric analysis was conducted on key influencing factors, including the initial crack size, initial crack location, and initial crack angle. The results reveal that these factors exert varying degrees of influence on the fatigue life and crack propagation paths of welded joints. Among them, the position of the initial crack along the length direction of the fillet weld has the most significant impact on the fatigue life of cross-shaped welded joints. Full article

Electromagnetic separators are widely used in new energy battery purification, resource recycling, and mineral processing. However, coil heating can cause a decline in separation performance and damage to coil insulation. To ensure the stable operation of electromagnetic separators, cooling plates are employed to effectively mitigate temperature rise. To explore a high-performance and economical cooling method, this paper employs CFD finite element analysis for the structural optimization of cooling plates. First, the paper investigates the flow heat characteristics of S-shaped cooling plates. Numerical simulations are performed to analyze the variation of fluid characteristics with different numbers of water channels. Regression equations linking structural parameters to performance indicators are derived, and the optimal channel number and hydraulic diameter are determined. Furthermore, to enhance heat transfer efficiency, an innovative semicircular groove structure is introduced on the cooling plate walls. An optimization strategy based on a genetic algorithm is developed to determine the optimal groove parameters. A simulation shows that the optimized cooling plate reduces coil temperature by 12.63 °C with a decrease of 15.31% compared with the original design. Finally, a prototype with optimized parameters is manufactured after the experimental results of the two test points and the simulation results reveal errors of 0.26% and 0.96%, respectively. The experimental results align well with the simulations, confirming the reliability of the experimental results and the feasibility of the optimization strategy, and providing a reference for future cooling plate designs. Full article