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Search Results (884)

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Keywords = highspeed camera

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23 pages, 5974 KiB  
Article
Gas–Liquid Two-Phase Flow in a Hydraulic Braking Pipeline: Flow Pattern and Bubble Characteristics
by Xiaolu Li, Yiyu Ke, Cangsu Xu, Jia Sun and Mingxuan Liang
Fluids 2025, 10(8), 196; https://doi.org/10.3390/fluids10080196 - 29 Jul 2025
Viewed by 201
Abstract
An in-depth analysis of the two-phase flow in a hydraulic braking pipeline can reveal its evolution process pertinent for designing and maintaining the hydraulic system. In this study, a high-speed camera examined the two-phase flow pattern and bubble characteristics in a hydraulic braking [...] Read more.
An in-depth analysis of the two-phase flow in a hydraulic braking pipeline can reveal its evolution process pertinent for designing and maintaining the hydraulic system. In this study, a high-speed camera examined the two-phase flow pattern and bubble characteristics in a hydraulic braking pipeline. Bubble flow pattern recognition, bubble segmentation, and bubble tracking were performed to analyze the bubble movement, including its behavior, distribution, velocity, and acceleration. The results indicate that the gas–liquid two-phase flow patterns in the hydraulic braking pipeline include bubbly, slug, plug, annular, and transient flows. Experiments reveal that bubbly flow is the most frequent, followed by slug, plug, and transient flows. However, plug and transient flows are unstable, while annular flow occurs at a wheel speed of 200 r/min. Bubbles predominantly appear in the upper section of the pipeline. Furthermore, large bubbles travel faster than small bubbles, whereas slug flow bubbles exhibit higher velocities than those in plug or transient flows. Full article
(This article belongs to the Special Issue Hydraulic Flow in Pipelines)
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8 pages, 2537 KiB  
Proceeding Paper
Theoretical and Experimental Research on Centrifugal Casting of Short and Long Castings
by Angel Velikov, Ivan Georgiev, Boyko Krastev and Krum Petrov
Eng. Proc. 2025, 100(1), 58; https://doi.org/10.3390/engproc2025100058 - 28 Jul 2025
Viewed by 93
Abstract
The technological process of the centrifugal casting of short and long castings is examined during development. The values of the technological parameters at applying heat-resistant coating on the working surface of metal molds were established. With a high-speed camera, the temperature of the [...] Read more.
The technological process of the centrifugal casting of short and long castings is examined during development. The values of the technological parameters at applying heat-resistant coating on the working surface of metal molds were established. With a high-speed camera, the temperature of the free surface during the pouring of the melts was measured. Research experiments were conducted. A mathematical model of the centrifugal casting process with a horizontal axis was created. Full article
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18 pages, 4836 KiB  
Article
Deep Learning to Analyze Spatter and Melt Pool Behavior During Additive Manufacturing
by Deepak Gadde, Alaa Elwany and Yang Du
Metals 2025, 15(8), 840; https://doi.org/10.3390/met15080840 - 28 Jul 2025
Viewed by 350
Abstract
To capture the complex metallic spatter and melt pool behavior during the rapid interaction between the laser and metal material, high-speed cameras are applied to record the laser powder bed fusion process and generate a large volume of image data. In this study, [...] Read more.
To capture the complex metallic spatter and melt pool behavior during the rapid interaction between the laser and metal material, high-speed cameras are applied to record the laser powder bed fusion process and generate a large volume of image data. In this study, four deep learning algorithms are applied: YOLOv5, Fast R-CNN, RetinaNet, and EfficientDet. They are trained by the recorded videos to learn and extract information on spatter and melt pool behavior during the laser powder bed fusion process. The well-trained models achieved high accuracy and low loss, demonstrating strong capability in accurately detecting and tracking spatter and melt pool dynamics. A stability index is proposed and calculated based on the melt pool length change rate. Greater index value reflects a more stable melt pool. We found that more spatters were detected for the unstable melt pool, while fewer spatters were found for the stable melt pool. The spatter’s size can affect its initial ejection speed, and large spatters are ejected slowly while small spatters are ejected rapidly. In addition, more than 58% of detected spatters have their initial ejection angle in the range of 60–120°. These findings provide a better understanding of spatter and melt pool dynamics and behavior, uncover the influence of melt pool stability on spatter formation, and demonstrate the correlation between the spatter size and its initial ejection speed. This work will contribute to the extraction of important information from high-speed recorded videos for additive manufacturing to reduce waste, lower cost, enhance part quality, and increase process reliability. Full article
(This article belongs to the Special Issue Machine Learning in Metal Additive Manufacturing)
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48 pages, 753 KiB  
Review
Shaping Training Load, Technical–Tactical Behaviour, and Well-Being in Football: A Systematic Review
by Pedro Afonso, Pedro Forte, Luís Branquinho, Ricardo Ferraz, Nuno Domingos Garrido and José Eduardo Teixeira
Sports 2025, 13(8), 244; https://doi.org/10.3390/sports13080244 - 25 Jul 2025
Viewed by 275
Abstract
Football performance results from the dynamic interaction between physical, tactical, technical, and psychological dimensions—each of which also influences player well-being, recovery, and readiness. However, integrated monitoring approaches remain scarce, particularly in youth and sub-elite contexts. This systematic review screened 341 records from PubMed, [...] Read more.
Football performance results from the dynamic interaction between physical, tactical, technical, and psychological dimensions—each of which also influences player well-being, recovery, and readiness. However, integrated monitoring approaches remain scarce, particularly in youth and sub-elite contexts. This systematic review screened 341 records from PubMed, Scopus, and Web of Science, with 46 studies meeting the inclusion criteria (n = 1763 players; age range: 13.2–28.7 years). Physical external load was reported in 44 studies using GPS-derived metrics such as total distance and high-speed running, while internal load was examined in 36 studies through session-RPE (rate of perceived exertion × duration), heart rate zones, training impulse (TRIMP), and Player Load (PL). A total of 22 studies included well-being indicators capturing fatigue, sleep quality, stress levels, and muscle soreness, through tools such as the Hooper Index (HI), the Total Quality Recovery (TQR) scale, and various Likert-type or composite wellness scores. Tactical behaviours (n = 15) were derived from positional tracking systems, while technical performance (n = 7) was assessed using metrics like pass accuracy and expected goals, typically obtained from Wyscout® or TRACAB® (a multi-camera optical tracking system). Only five studies employed multivariate models to examine interactions between performance domains or to predict well-being outcomes. Most remained observational, relying on descriptive analyses and examining each domain in isolation. These findings reveal a fragmented approach to player monitoring and a lack of conceptual integration between physical, psychological, tactical, and technical indicators. Future research should prioritise multidimensional, standardised monitoring frameworks that combine contextual, psychophysiological, and performance data to improve applied decision-making and support player health, particularly in sub-elite and youth populations. Full article
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28 pages, 42031 KiB  
Article
A Building Crack Detection UAV System Based on Deep Learning and Linear Active Disturbance Rejection Control Algorithm
by Lei Zhang, Lili Gong, Le Wang, Zhou Wang and Song Yan
Electronics 2025, 14(15), 2975; https://doi.org/10.3390/electronics14152975 - 25 Jul 2025
Viewed by 161
Abstract
This paper presents a UAV-based building crack real-time detection system that integrates an improved YOLOv8 algorithm with Linear Active Disturbance Rejection Control (LADRC). The system is equipped with a high-resolution camera and sensors to capture high-definition images and height information. First, a trajectory [...] Read more.
This paper presents a UAV-based building crack real-time detection system that integrates an improved YOLOv8 algorithm with Linear Active Disturbance Rejection Control (LADRC). The system is equipped with a high-resolution camera and sensors to capture high-definition images and height information. First, a trajectory tracking controller based on LADRC was designed for the UAV, which uses a linear extended state observer to estimate and compensate for unknown disturbances such as wind interference, significantly enhancing the flight stability of the UAV in complex environments and ensuring stable crack image acquisition. Secondly, we integrated Convolutional Block Attention Module (CBAM) into the YOLOv8 model, dynamically enhancing crack feature extraction through both channel and spatial attention mechanisms, thereby improving recognition robustness in complex backgrounds. Lastly, a skeleton extraction algorithm was applied for the secondary processing of the segmented cracks, enabling precise calculations of crack length and average width and outputting the results to a user interface for visualization. The experimental results demonstrate that the system successfully identifies and extracts crack regions, accurately calculates crack dimensions, and enables real-time monitoring through high-speed data transmission to the ground station. Compared to traditional manual inspection methods, the system significantly improves detection efficiency while maintaining high accuracy and reliability. Full article
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25 pages, 4424 KiB  
Article
Pool Boiling Heat Transfer of Ethanol on Surfaces with Minichannels
by Robert Pastuszko
Energies 2025, 18(15), 3938; https://doi.org/10.3390/en18153938 - 23 Jul 2025
Viewed by 243
Abstract
In this paper, the pool boiling of ethanol was analyzed. The experiments were carried out at atmospheric pressure. Heat transfer surfaces in the form of deep minichannels were made of copper. The channels with a depth of 0.2 to 0.5 mm were milled [...] Read more.
In this paper, the pool boiling of ethanol was analyzed. The experiments were carried out at atmospheric pressure. Heat transfer surfaces in the form of deep minichannels were made of copper. The channels with a depth of 0.2 to 0.5 mm were milled in parallel. The width of the minichannels was 0.6–1.2 mm, and the depth was 5.5, 6, and 10 mm. The highest heat transfer coefficient, 52 kW/m2K, was achieved for the minichannels with a depth of 6 mm and a width of 0.8 mm. The maximum heat flux of 953 kW/m2 was produced using minichannels 5.5 mm deep and 0.5 mm wide. An over threefold increase in the heat transfer coefficient and over a twofold increase in the maximum heat flux in relation to the plain surface were obtained. In the heat flux range 21.2–1035 kW/m2, the influence of channel width and depth on the heat exchange process was determined. The diameters of the detaching vapor bubbles were determined on the experimental setup using a high-speed camera. An analytical model was developed to determine the diameter of the departing bubble for the analyzed enhanced surfaces. The model correctly represented the changes in bubble diameter with increasing heat flux. Full article
(This article belongs to the Special Issue Heat Transfer Analysis: Recent Challenges and Applications)
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18 pages, 5434 KiB  
Article
Design and Experimental Validation of Stem-Clamping-and-Pull-Out-Type Pepper Plug Seedling-Picking Mechanism
by Zhenhua Lin, Xiao Li, Hao Sun, Maile Zhou, Jianjun Yin, Jijia He and Daqing Yin
Agriculture 2025, 15(14), 1563; https://doi.org/10.3390/agriculture15141563 - 21 Jul 2025
Viewed by 173
Abstract
As a core component of a fully automatic pepper transplanter, the performance of the seedling-picking mechanism is of particular significance. However, existing seedling-picking mechanisms have problems such as being prone to damaging the seedling roots and substrate, as well as having poor stability. [...] Read more.
As a core component of a fully automatic pepper transplanter, the performance of the seedling-picking mechanism is of particular significance. However, existing seedling-picking mechanisms have problems such as being prone to damaging the seedling roots and substrate, as well as having poor stability. To develop a highly efficient, stable, and minimally damaging seedling-picking mechanism, this study proposed a design scheme for a stem-clamping-and-pulling-out-type seedling-picking end actuator driven by a non-circular gear system. The specific methods and objectives include the following: (1) designing a differential non-circular gear system to replicate a manual picking trajectory accurately; (2) establishing a kinematic model and developing optimization software to determine the optimal parameter combination; (3) experimentally validating the mechanism’s performance through virtual simulations and bench tests. The bench tests showed that the mechanism could complete two seedling-picking operations per rotation, extracting an entire row (eight plants) in a single rotation at a speed of 30 r/min. The measured angles of the end effector at four key postures were highly consistent with simulation and high-speed camera data, with all key posture errors less than 1°. These results demonstrate the mechanism’s high accuracy, efficiency, and reliability. Full article
(This article belongs to the Section Agricultural Technology)
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17 pages, 33742 KiB  
Article
Experimental Study of Aerodynamic and Bird Exclusion Characteristics of a Branched Turboprop Inlet Under Ground Suction Conditions
by Ge Zhou, Zhenlong Wu and Huijun Tan
Aerospace 2025, 12(7), 640; https://doi.org/10.3390/aerospace12070640 - 19 Jul 2025
Viewed by 193
Abstract
A turboprop aircraft is exposed to the risk of bird strikes during flight, which may have a serious impact on flight safety once the bird is sucked into the engine. In this study, the aerodynamic and bird exclusion characteristics of a branched turboprop [...] Read more.
A turboprop aircraft is exposed to the risk of bird strikes during flight, which may have a serious impact on flight safety once the bird is sucked into the engine. In this study, the aerodynamic and bird exclusion characteristics of a branched turboprop inlet were tested on a branched turboprop inlet–bird striking experiment system under ground suction conditions. The ingestion processes of the bird were captured by a high-speed camera system. The static pressure at the inner wall of the inlet during the ingestion process was measured. The results indicate that when a low-speed bird at a large incident angle impacts on the wall of the inlet near the lower lip under ground suction conditions, the bird is easily sucked into the core duct. Conversely, it is more likely to be excluded by the bypass duct. Moreover, when the bird moves into the inlet, the static pressure on the wall of the area where it passes through increases significantly. Full article
(This article belongs to the Special Issue Environmental Influences on Aircraft Aerodynamics)
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19 pages, 5968 KiB  
Article
Investigation of Electrical Discharge Processes During Electrolytic–Plasma Nitrocarburizing
by Bauyrzhan Rakhadilov, Laila Sulyubayeva, Almasbek Maulit and Temirlan Alimbekuly
Materials 2025, 18(14), 3381; https://doi.org/10.3390/ma18143381 - 18 Jul 2025
Viewed by 352
Abstract
In this study, the process of electrolytic–plasma nitrocarburizing (EPNC) of 20-grade steel was investigated using various electrolytes and temperature regimes. At the first stage, optical spectral analysis of plasma emission during EPNC was carried out with spectral registration in the range of 275–850 [...] Read more.
In this study, the process of electrolytic–plasma nitrocarburizing (EPNC) of 20-grade steel was investigated using various electrolytes and temperature regimes. At the first stage, optical spectral analysis of plasma emission during EPNC was carried out with spectral registration in the range of 275–850 nm, which allowed the identification of active components (Hα, CN, Fe I, O I lines, etc.) and the calculation of electron density. Additionally, the EPNC process was recorded using a high-speed camera (1500 frames per second), which made it possible to visually evaluate the dynamics of arc and glow discharges under varying electrolyte compositions. At the next stage, the influence of temperature regimes (650 °C, 750 °C, and 850 °C) on the formation of the hardened layer was studied. Using SEM and EDS methods, the morphology, phase zones, and the distribution of chemical elements were determined. Microhardness measurements along the depth and friction tests were carried out. It was found that a temperature of 750 °C provides the best balance between the uniformity of chemical composition, high microhardness (~800 HV), and a minimal coefficient of friction (~0.48). The obtained results confirm the potential of the selected EPNC regime for improving the performance characteristics of 20-grade steel. Full article
(This article belongs to the Section Metals and Alloys)
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22 pages, 5418 KiB  
Article
TickRS: A High-Speed Gapless Signal Sampling Method for Rolling-Shutter Optical Camera Communication
by Yongfeng Hong, Xiangting Xie and Xingfa Shen
Photonics 2025, 12(7), 720; https://doi.org/10.3390/photonics12070720 - 16 Jul 2025
Viewed by 148
Abstract
Using the rolling-shutter mechanism to enhance the signal sampling frequency of Optical Camera Communication (OCC) is a low-cost solution, but its periodic sampling interruptions may cause signal loss, and existing solutions often compromise communication rate and distance. To address this, this paper proposes [...] Read more.
Using the rolling-shutter mechanism to enhance the signal sampling frequency of Optical Camera Communication (OCC) is a low-cost solution, but its periodic sampling interruptions may cause signal loss, and existing solutions often compromise communication rate and distance. To address this, this paper proposes NoGap-RS, a no-gap sampling method, theoretically addressing the signal loss issue at longer distances from a perspective of CMOS exposure timing. Experiments show that NoGap-OOK, a OCC system based on NoGap-RS and On-Off key modulation, can achieve a communication rate of 6.41 Kbps at a distance of 3 m, with a BER of 105 under indoor artificial light. This paper further proposes TickRS, a time slot division method, innovatively addressing the overlap that occurs during consecutive-row exposures to further enhance communication rate. Experiments show that TickRS-CSK, a OCC system based on TickRS and Color-Shift Key, can achieve a communication rate of 20.09 Kbps at a distance of 3.6 m, with a BER of 102 under indoor natural light. Full article
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31 pages, 7931 KiB  
Article
Enhanced Pool Boiling via Binder-Jetting 3D-Printed Porous Copper Structures: CHF and HTC Investigation
by Lilian Aketch Okwiri, Takeshi Mochizuki, Kairi Koito, Noriaki Fukui and Koji Enoki
Appl. Sci. 2025, 15(14), 7892; https://doi.org/10.3390/app15147892 - 15 Jul 2025
Viewed by 248
Abstract
The escalating heat flux densities in high-performance electronics necessitate superior thermal management. This study enhanced pool-boiling heat transfer, a method offering high heat removal capacity, by leveraging Binder Jetting 3D Printing (BJ3DP) to create complex porous copper structures without the need for chemical [...] Read more.
The escalating heat flux densities in high-performance electronics necessitate superior thermal management. This study enhanced pool-boiling heat transfer, a method offering high heat removal capacity, by leveraging Binder Jetting 3D Printing (BJ3DP) to create complex porous copper structures without the need for chemical treatments. This approach enables a reliable utilization of phenomena like capillarity for improved performance. Three types of porous copper structures, namely Large Lattice, Small Lattice, and Staggered, were fabricated on pure copper substrates and tested via pool boiling of de-ionized and de-gassed water at atmospheric pressure. Compared to a plain polished copper surface, which exhibited a critical heat flux (CHF) of 782 kW/m2 at a wall superheat of 18 K, the 3D-printed porous copper surfaces showed significantly improved heat transfer performance. The Staggered surface achieved a conventional CHF of 2342.4 kW/m2 (a 199.7% enhancement) at a wall superheat of 24.6 K. Notably, the Large Lattice and Small Lattice structures demonstrated exceptionally stable boiling without reaching the typical catastrophic CHF within the experimental parameters. These geometries continued to increase in heat flux, reaching maximums of 2397.7 kW/m2 (206.8% higher at a wall superheat of 55.6 K) and 2577.2 kW/m2 (229.7% higher at a wall superheat of 39.5 K), respectively. Subsequently, a gradual decline in heat flux was observed with an increasing wall superheat, demonstrating an outstanding resistance to the boiling crisis. These improvements are attributed to the formation of distinct vapor–liquid pathways within the porous structures, which promotes the efficient rewetting of the heated surface through capillary action. This mechanism supports a highly efficient, self-sustaining boiling configuration, emphasizing the superior rewetting and vapor management capabilities of these 3D-printed porous structures, which extend the boundaries of sustained high heat flux performance. The porous surfaces also demonstrated a higher heat transfer coefficient (HTC), particularly at lower heat fluxes (≤750 kW/m2). High-speed digital camera visualization provided further insight into the boiling phenomenon. Overall, the findings demonstrate that these BJ3DP structured surfaces produce optimized vapor–liquid pathways and capillary-enhanced rewetting, offering significantly superior heat transfer performance compared to smooth surfaces and highlighting their potential for advanced thermal management. Full article
(This article belongs to the Section Energy Science and Technology)
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22 pages, 6123 KiB  
Article
Real-Time Proprioceptive Sensing Enhanced Switching Model Predictive Control for Quadruped Robot Under Uncertain Environment
by Sanket Lokhande, Yajie Bao, Peng Cheng, Dan Shen, Genshe Chen and Hao Xu
Electronics 2025, 14(13), 2681; https://doi.org/10.3390/electronics14132681 - 2 Jul 2025
Viewed by 480
Abstract
Quadruped robots have shown significant potential in disaster relief applications, where they have to navigate complex terrains for search and rescue or reconnaissance operations. However, their deployment is hindered by limited adaptability in highly uncertain environments, especially when relying solely on vision-based sensors [...] Read more.
Quadruped robots have shown significant potential in disaster relief applications, where they have to navigate complex terrains for search and rescue or reconnaissance operations. However, their deployment is hindered by limited adaptability in highly uncertain environments, especially when relying solely on vision-based sensors like cameras or LiDAR, which are susceptible to occlusions, poor lighting, and environmental interference. To address these limitations, this paper proposes a novel sensor-enhanced hierarchical switching model predictive control (MPC) framework that integrates proprioceptive sensing with a bi-level hybrid dynamic model. Unlike existing methods that either rely on handcrafted controllers or deep learning-based control pipelines, our approach introduces three core innovations: (1) a situation-aware, bi-level hybrid dynamic modeling strategy that hierarchically combines single-body rigid dynamics with distributed multi-body dynamics for modeling agility and scalability; (2) a three-layer hybrid control framework, including a terrain-aware switching MPC layer, a distributed torque controller, and a fast PD control loop for enhanced robustness during contact transitions; and (3) a multi-IMU-based proprioceptive feedback mechanism for terrain classification and adaptive gait control under sensor-occluded or GPS-denied environments. Together, these components form a unified and computationally efficient control scheme that addresses practical challenges such as limited onboard processing, unstructured terrain, and environmental uncertainty. A series of experimental results demonstrate that the proposed method outperforms existing vision- and learning-based controllers in terms of stability, adaptability, and control efficiency during high-speed locomotion over irregular terrain. Full article
(This article belongs to the Special Issue Smart Robotics and Autonomous Systems)
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10 pages, 8944 KiB  
Article
High-Speed Full-Color Polarized Light Imaging of Collagen Using a Polarization Camera
by Bin Yang, Neil Nayyar and Billy Sanchez
Bioengineering 2025, 12(7), 720; https://doi.org/10.3390/bioengineering12070720 - 30 Jun 2025
Viewed by 345
Abstract
Polarized light imaging (PLI) has been effective in visualizing and quantifying collagen content. Collagen-specific data are often overlaid over the tissue image for visualization. However, such contextual tissue images are typically in grayscale and lack important color information, limiting the usefulness of PLI [...] Read more.
Polarized light imaging (PLI) has been effective in visualizing and quantifying collagen content. Collagen-specific data are often overlaid over the tissue image for visualization. However, such contextual tissue images are typically in grayscale and lack important color information, limiting the usefulness of PLI in imaging the stained histology slides and for surgical guidance. The objective of this study was to develop a robust and easy-to-implement PLI technique to capture both true color and birefringent collagen data, and we call it ColorPOL. ColorPOL uses only one polarization-sensitive camera to capture information at 75 frames per second. The true color images were synthesized from individual RGB images, and collagen-specific information (fiber orientation and retardance) was derived from the green channel image. We implemented ColorPOL in transmission mode on an upright microscope and in reflection mode for wide-field thick tissue imaging. The color images in both implementations provided valuable color tissue context that facilitated the identification and localization of collagen content. Additionally, we demonstrated that in reflection mode, the high imaging speed enabled us to record and visualize continuous deformations of the collagenous tissues (tendons, sciatic nerves, and blood vessels) overlaid on the processed collagen-specific information. Robust performance and flexible configuration will make ColorPOL a valuable tool in basic research and translational applications. Full article
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34 pages, 3719 KiB  
Article
Experimental and Numerical Study of Film Boiling Around a Small Nickel Sphere
by Charles Brissot, Léa Cailly-Brandstäter, Romain Castellani, Elie Hachem and Rudy Valette
Fluids 2025, 10(7), 162; https://doi.org/10.3390/fluids10070162 - 24 Jun 2025
Viewed by 233
Abstract
This work—mixing an original experimental approach, as well as numerical simulations—proposes to study film boiling modes around a small nickel sphere. While dealing with a simple looking phenomenon that is found in many industrial processes and has been solved for basic quenching regimes, [...] Read more.
This work—mixing an original experimental approach, as well as numerical simulations—proposes to study film boiling modes around a small nickel sphere. While dealing with a simple looking phenomenon that is found in many industrial processes and has been solved for basic quenching regimes, we focus on describing precisely how vapor formation and film thicknesses, as well as vapor bubble evacuation, affect cooling kinetics. As instrumenting small spheres may lead to experimental inaccuracies, we optically captured, using a high-speed camera, the vapor film thickness at mid height, the vapor bubble volume, and the bubble detachment frequency, along with the heat flux. More precisely, an estimation of the instant sphere temperature, in different conditions, was obtained through cooling time measurement before the end of the film boiling mode, subsequently facilitating heat flux evaluation. We encountered a nearly linear decrease in both the vapor film thickness and vapor bubble volume as the sphere temperature decreased. Notably, the detachment frequency remained constant across the whole temperature range. The estimation of the heat fluxes confirmed the prevalence of conduction as the primary heat transfer mode; a major portion of the energy was spent increasing the liquid temperature. The results were then compared to finite element simulations using an in-house multiphysics solver, including thermic phase changes (liquid to vapor) and their hydrodynamics, and we also captured the interfaces. While presenting a challenge due to the contrast in densities and viscosities between phases, the importance of the small circulations along them, which improve the heat removal in the liquid phase, was highlighted; we also assessed the suitability of the model and the numerical code for the simulation of such quenching cases when subcooling in the vicinity of a saturation temperature. Full article
(This article belongs to the Section Heat and Mass Transfer)
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23 pages, 5785 KiB  
Article
Method for Determining Contact Temperature of Tool Rake Face During Orthogonal Turning of Ti-6Al-4V Alloy
by Łukasz Ślusarczyk and Agnieszka Twardowska
Materials 2025, 18(13), 2980; https://doi.org/10.3390/ma18132980 - 24 Jun 2025
Viewed by 343
Abstract
This paper proposes a method for determining the contact temperature in the secondary shear zone. The input data include the results of the experimental tests of the orthogonal turning of a Ti-6Al-4V titanium workpiece using uncoated WC-Co tools with a flat rake face. [...] Read more.
This paper proposes a method for determining the contact temperature in the secondary shear zone. The input data include the results of the experimental tests of the orthogonal turning of a Ti-6Al-4V titanium workpiece using uncoated WC-Co tools with a flat rake face. The cutting force components were recorded using a piezoelectric dynamometer, a thermovision camera was used to record the temperature in the cutting zone, and a high-speed camera was used to record the chip-forming process. The independent variables included machining parameters, feed rate, cutting speed, and rake angle. A dual-zone thermomechanical cutting process model that accounted for the sticking and sliding areas was adapted for the identification of the heat flux in the chip–rake face contact zone. Then, based on the Shaw approach, the partition coefficients were determined for the contact temperature on the chip–tool tip contact. In addition, the results of the experimental tests allowed the determination of the relationship among the process parameters, friction coefficients, and the length of the contact of the chip with the tool rake face. A graphical visualization of the temperature distribution on the tool rake face was performed using the MATLAB PDE 3.9 software package. Although the application of the dual-zone model has been well presented in the literature, the results provided in this paper may be helpful in analyzing and modeling thermal phenomena in the secondary shear zone. Full article
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