This document summarizes research on the effect of 3D printed surface roughness on film cooling effectiveness. Experiments were conducted by manufacturing film cooling holes using different 3D printing techniques that resulted in varying surface roughness. Results showed major differences in film cooling effectiveness and span-averaged results between the 3D printed coupons compared to a standard CNC machined part due to increased surface roughness. Rougher surfaces delayed coolant separation in the holes and showed higher effectiveness at high blowing ratios, likely due to film diffusion preventing penetration into the mainstream flow. Further work is needed to understand the impact of build orientation and other manufacturing effects.
This research was a part of my Dual Degree Thesis and presented at The Minerals Metals and Materials Society Annual Meeting and Conference held at Seattle, WA in 2010.
This research was a part of my Dual Degree Thesis and presented at The Minerals Metals and Materials Society Annual Meeting and Conference held at Seattle, WA in 2010.
Analysis of process parameters in dry machining of en 31 steel by grey relati...IAEME Publication
This paper presents the optimization of surface roughness & material removal rate in dry turning of EN-31 steel.Carbide inserts were used for machining of EN-31 to study effects of process parameters [Cutting speed (S), Feed (F) and depth of cut (d)]. These models can be effectively used to predict the surface roughness (Ra) of the workpiece. The big challenge of the Micro, small& medium industries in India for achieving high quality products with increased productivity.Paper presentswork of an investigation of turning process parameters on EN-31 material, for optimization of surface roughness, material removal rate.The experiment is carried out by considering three controllable input variables namely cutting speed, feed rate, and depth of cut.The design of experiment and optimization of surface roughness is carried out by using Taguchi L9 orthogonal array & Grey Relational analysis.
Optimising drilling parameters of gfrp by using grey relational analysiseSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
Evaluation the Effect of Machining Parameters on MRR of Mild SteelIJSRD
Turning metal removal is the removal of metal outside diameter of a rotating cylindrical workpiece. As it is used to reduce the diameter. of the work piece generally to a specified dimension and to produce a smooth finish on the metal. Often, the work piece is turned so that the sections have different diameters. As is the machining operation that produces cylindrical. In its basic form, it can be defined as an outer surface machining: Based on the findings of the Pilot study, actual experimentation work will be designed and input machining parameters and their values finalized. The results are expected to show that the response variables (output parameters) strongly influenced by the control factors (input parameters). So, the results which are obtained after experimentation analyzed and modeled for their application in manufacturing industry It is concluded that for MRR be maximum factor Cutting speed has to be at high level 3, Feed has to be at high level & D.O.C has to be at high level.
A STUDY OF THE EFFECTS OF MACHINING PARAMETERS ON SURFACE ROUGHNESS USING RES...IAEME Publication
A series of experiments to determine the character of surface of the alloy steel have been conducted. The main objective of this work is to develop a holistic understanding of the effects of
feed rate, spindle speed, depth of cut and type of coolant on the surface roughness and to create a model for the conducted study. Such an understanding can provide sapience about the shortcomings of controlling the finish of machined surfaces when the process parameters are adjusted to obtain a certain surface finish. The model, which includes the effect of spindle speed, cutting feed rate and depth of cut, and any three variable interactions, predicted the surface roughness values.
Effect of process parameters using friction stir processing /welding of steel...Husain Mehdi
Microstructural changes and flow of material have be comprehensively studied by many researchers. A lot of studies have been conducted by changing the process parameters such as axial load, feed, speed of the tool, tool geometry, tool tilt angle etc. to find the optimum process parameters. Friction stir welding can be applied on various materials such as aluminum, manganese, copper. Till date majority of the research and development was done on aluminum alloys. This is so because Al alloys are easy to deform at relatively low temperatures (approximately below 550 Celsius). Also, they are easier to weld as compared to other materials. But these days a lot of studies are being conducted on carrying out friction stir processing on steel. This process improves mechanical properties like tensile strength, ductility, micro-hardness etc.
The big challenge of the mass production firms is concentrated for achieving high quality
products with good dimensionability with high productivity, less wear on the cutting insert, less use
of cutting fluid, within less time. This paper present dissertation work of an investigation of turning
process parameters on hard EN 31 material, for optimization of surface roughness, material removal
rate, machining time in wet and minimum quantity lubrication system. The experiment is carried out
by considering four controllable input variables namely cutting speed, feed rate, depth of cut and
insert nose radius in the presence of wet & MQL system. This experiment also present the relation
between chip formations and controllable variables along with chip thickness, chip colors & chip
velocity from which its effect on insert wear, quality of product can be easily found out, because of
chip morphology gives indirectly the effect of it on the insert wear. In this dissertation work
minimum quantity lubrication system is used for reducing the cutting zone temperature properly and
very fastly. Finally comparison is carried out between wet and minimum quantity lubrication system
from which one can easily identify which system is better for higher productivity along with high
surface finish. This work also present the productivity (MRR) concept in production. The design of
experiment and optimization of surface roughness, material removal rate, machining time is carried
out by using response surface methodology (RSM). Central composite design method is used (CCD)
for the total experimental design work and its analysis and also for optimization of turning process
parameter by which wastage of the machining time, power can be avoided.
Analysis of process parameters in dry machining of en 31 steel by grey relati...IAEME Publication
This paper presents the optimization of surface roughness & material removal rate in dry turning of EN-31 steel.Carbide inserts were used for machining of EN-31 to study effects of process parameters [Cutting speed (S), Feed (F) and depth of cut (d)]. These models can be effectively used to predict the surface roughness (Ra) of the workpiece. The big challenge of the Micro, small& medium industries in India for achieving high quality products with increased productivity.Paper presentswork of an investigation of turning process parameters on EN-31 material, for optimization of surface roughness, material removal rate.The experiment is carried out by considering three controllable input variables namely cutting speed, feed rate, and depth of cut.The design of experiment and optimization of surface roughness is carried out by using Taguchi L9 orthogonal array & Grey Relational analysis.
Optimising drilling parameters of gfrp by using grey relational analysiseSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
Evaluation the Effect of Machining Parameters on MRR of Mild SteelIJSRD
Turning metal removal is the removal of metal outside diameter of a rotating cylindrical workpiece. As it is used to reduce the diameter. of the work piece generally to a specified dimension and to produce a smooth finish on the metal. Often, the work piece is turned so that the sections have different diameters. As is the machining operation that produces cylindrical. In its basic form, it can be defined as an outer surface machining: Based on the findings of the Pilot study, actual experimentation work will be designed and input machining parameters and their values finalized. The results are expected to show that the response variables (output parameters) strongly influenced by the control factors (input parameters). So, the results which are obtained after experimentation analyzed and modeled for their application in manufacturing industry It is concluded that for MRR be maximum factor Cutting speed has to be at high level 3, Feed has to be at high level & D.O.C has to be at high level.
A STUDY OF THE EFFECTS OF MACHINING PARAMETERS ON SURFACE ROUGHNESS USING RES...IAEME Publication
A series of experiments to determine the character of surface of the alloy steel have been conducted. The main objective of this work is to develop a holistic understanding of the effects of
feed rate, spindle speed, depth of cut and type of coolant on the surface roughness and to create a model for the conducted study. Such an understanding can provide sapience about the shortcomings of controlling the finish of machined surfaces when the process parameters are adjusted to obtain a certain surface finish. The model, which includes the effect of spindle speed, cutting feed rate and depth of cut, and any three variable interactions, predicted the surface roughness values.
Effect of process parameters using friction stir processing /welding of steel...Husain Mehdi
Microstructural changes and flow of material have be comprehensively studied by many researchers. A lot of studies have been conducted by changing the process parameters such as axial load, feed, speed of the tool, tool geometry, tool tilt angle etc. to find the optimum process parameters. Friction stir welding can be applied on various materials such as aluminum, manganese, copper. Till date majority of the research and development was done on aluminum alloys. This is so because Al alloys are easy to deform at relatively low temperatures (approximately below 550 Celsius). Also, they are easier to weld as compared to other materials. But these days a lot of studies are being conducted on carrying out friction stir processing on steel. This process improves mechanical properties like tensile strength, ductility, micro-hardness etc.
The big challenge of the mass production firms is concentrated for achieving high quality
products with good dimensionability with high productivity, less wear on the cutting insert, less use
of cutting fluid, within less time. This paper present dissertation work of an investigation of turning
process parameters on hard EN 31 material, for optimization of surface roughness, material removal
rate, machining time in wet and minimum quantity lubrication system. The experiment is carried out
by considering four controllable input variables namely cutting speed, feed rate, depth of cut and
insert nose radius in the presence of wet & MQL system. This experiment also present the relation
between chip formations and controllable variables along with chip thickness, chip colors & chip
velocity from which its effect on insert wear, quality of product can be easily found out, because of
chip morphology gives indirectly the effect of it on the insert wear. In this dissertation work
minimum quantity lubrication system is used for reducing the cutting zone temperature properly and
very fastly. Finally comparison is carried out between wet and minimum quantity lubrication system
from which one can easily identify which system is better for higher productivity along with high
surface finish. This work also present the productivity (MRR) concept in production. The design of
experiment and optimization of surface roughness, material removal rate, machining time is carried
out by using response surface methodology (RSM). Central composite design method is used (CCD)
for the total experimental design work and its analysis and also for optimization of turning process
parameter by which wastage of the machining time, power can be avoided.
Analysis of Process Parameters for Optimization of Plastic Extrusion in Pipe ...IJERA Editor
The objective of this paper is to study the defects in the plastic pipe, to optimize the plastic pipe manufacturing process. It is very essential to learn the process parameter and the defect in the plastic pipe manufacturing process to optimize it. For the optimization Taguchi techniques is used in this paper. For the research work Shivraj HY-Tech Drip Irrigation pipe manufacturing, Company was selected. This paper is specifically design for the optimization in the current process. The experiment was analyzed using commercial Minitab16 software, interpretation has made, and optimized factor settings were chosen. After prediction of result the quality loss is calculated and it is compare with before implementation of DOE. The research works has improves the Production, quality and optimizes the process.
International Journal of Engineering Research and Development (IJERD)IJERD Editor
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“Gray Relational Based Analysis of Al-6351”iosrjce
IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE) is a double blind peer reviewed International Journal that provides rapid publication (within a month) of articles in all areas of mechanical and civil engineering and its applications. The journal welcomes publications of high quality papers on theoretical developments and practical applications in mechanical and civil engineering. Original research papers, state-of-the-art reviews, and high quality technical notes are invited for publications.
Study of effect of process parameter setting on porosity levels of aluminium ...IOSR Journals
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aluminium alloy SAE 308 by using Taguchi method. In any die casting industry porosity is a very serious
problem faced by production department and also being an invisible defect it is not identified visually in running
production. It is shown in this work that die casting parameters which are related with machine such as first
phase speed, second phase speed, first phase length and injection pressure all have significant influence on
porosity level. The quality assessment of the die casting part was based on porosity measurement. The
experiment have been performed as per the combination of levels of different process parameters suggested by
L9 orthogonal array and conformation experiments have been performed to validate the optimum levels of
different parameters
Process parameter optimization of SLM process and application of Taguchi appr...ijsrd.com
Selective Laser Melting (SLM) is an emerging powder based additive layer manufacturing technology that used to fabricate three-dimensional fully functional parts from metal powders by fusing the material in a layer by layer manner as per a CAD model. The quality of SLM produced parts is significantly affected by various manufacturing parameters of SLM machine. Hence optimization of SLM process parameters is necessary in order to improve the quality of parts. The purpose of this paper is to explore the reviews for various optimization methods used for process parameter optimization of SLM process and application of Taguchi approach. This review of work can be helpful to the other researchers to carry out further work in the same era.
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1. Dependence of Film Cooling
Effectiveness on 3D Printed
Cooling Holes
Presented By:
Paul Aghasi
GT2016-56698, June 14th 2016
Paul Aghasi, MSc
Ephraim Gutmark, PhD
David Munday, PhD
Authors, University of Cincinnati:
2. Outline
• Experimental Approach and Motivation
• Relevant Previous Work
• Data Quality and Facility Validation
• Experimental Results
• Discussion and Conclusion
• Backup Slides
2GT2016-56698
3. Supply System and Wind Tunnel
3GT2016-56698
Facility Capabilities:
Air Mass flow: up to 3.0 lbm/s
Coolant Mass flow: up to 0.05 lbm/s
Mainstream Mach: up to 0.8
Available Air at Highest Mass Flow: 30 mins
4. Film Hole Geometry
• (a) CNC Aluminum
• (b) SLA
• (c) PolyJet
• (d-f) FDM, 200-250-
300μ build layer
resolutions
1Schroeder R. P., and Thole K. A., 2014. "Adiabatic Effectiveness Measurements For A Baseline Shaped Film Cooling Hole," in Proceedings of ASME Turbo Expo, Düsseldorf,
Germany,
1
Objective:
Similar performance?
If not why?
4GT2016-56698
5. Roughness and Diffusers
• Ra/D = 0.005
• Added roughness
caused:
– Flow separation
prevention
– BL thickening at the
throat and effective
divergence angle
reduction
1Persh and Bailey B. M., 1954."Effect of Surface Roughness Over the Downstream Region of a 23° Conical Diffuser," NACA TN 3066,
1
5GT2016-56698
u/U
6. Factors Affecting Part Quality
• Stair stepping effect
• Build orientation
• Surface roughness is method
dependent
• 90° build angle surface roughness
can be related to the 60° build
angle surface roughness
– True for SLA and FDM
– Inverted for PolyJet
30°
1Ahn D., Kim H., and Lee S., 2009. "Surface roughness prediction using measured data and interpolation in layered manufacturing," Journal of Materials
Processing Technology, 209, pp. 664-671,
2Kim G. D., and Oh Y. T., 2008. "A benchmark study on rapid prototyping processes and machines: quantitative comparisons of mechanical properties,
accuracy, roughness, speed, and material cost," Journal of Engineering Manufacture, 222 (2), pp. 201-215,
2
2
1
6GT2016-56698
2
7. Data Quality – PSP Validation
1Baldauf S., Schulz A., and Wittig S., 2001. "High-Resolution Measurements of Local
Effectiveness From Discrete Hole Film Cooling," ASME Journal of Turbomachinery, 123
(4), pp. 758-765,
δ/D = 0.4
δ/D = 0.1
7GT2016-56698
8. Experimental Flow Conditions
• Mainstream Mach 0.3 for all cases
• Approach Rex= 9 X 105 > 5 X 105
• CO2 as coolant, density ratio = 1.5
– Mass transfer analogy
• Test conditions:
Blowing Ratio (BR) 1.0 1.5 2.0 2.5 3.0 3.5
Momentum flux ratio (I) 0.58 1.18 1.85 2.52 3.16 3.76
8GT2016-56698
12. Comparison of various test coupons
at BR = 2.0, 1.85
Comparison of various test coupons at
BR = 1.5, I = 1.18
Full Field Effectiveness
12GT2016-56698
13. Comparison of various test coupons at
BR = 3.5, I = 3.76
Full Field η
13GT2016-56698
0 0
0 0
0 0
14. Lift off 2.5
Lift off >3.5
Lift off 2.0Lift off 2.0
Lift off 3.0 Lift off 3.5
Span Averaged Results
14GT2016-56698
0 0 0
0 0 0
15. Discussion and Conclusion
• OSP increased Ra for aluminum
• Major differences in η and η̅ for 3D printed coupons
– Care needs to be taken when testing 3D printed film holes.
• In-hole coolant separation was delayed for rougher parts
– Most likely due to boundary layer thickening at the diffuser
section1
– The exception is the PolyJet coupon
• Rougher test coupons showed higher η̅ at BR of 3.5
– Due to the film diffusion on the rough surface that prevents it
from penetrating into the mainstream2
• At this scale the roughness produced by additive
manufacturing is not comparable to the less rough, standard
CNC machined parts.
1Persh and Bailey B. M., 1954."Effect of Surface Roughness Over the Downstream Region of a 23° Conical Diffuser," NACA TN
3066,
2Goldstein, R. J. Eckert, E. R. G. Chiang, H. D. and Elovic, E. 1985. "Effect of Surface Roughness on Film Cooling Performance,"
Journal of Engineering for Gas Turbines and Power , 107, pp. 111-116,
15GT2016-56698
16. Future Work
• Build orientation
• Roughness effects from the paint
• Hot wire measurements
– Oversized holes
• Metal 3D printing and its effect
– Its build orientation
• Assess CFD validation
16GT2016-56698