1. The document details the design, manufacturing, and testing of a model steam engine intended as a teaching aid.
2. Various components of the engine were created using CAD software and then manufactured through methods like 3-axis machining, die casting, fabrication, and rapid prototyping.
3. Extensive testing was performed on the key pressurized boiler component and the fully assembled engine was tested with compressed air to validate its safe operation.
APPLICATION OF HEAT INTEGRATION AND SEQUENCING IN THE DESIGN OF ENERGY EFFICI...Manish Sharma (LION)
Distillation is the most widely used separation technique. The downside of the technology is the high capital and energy cost. A small scale distillation comprises of feed to be separated in 3-4 products. With the application of heat integration and distillation sequencing, both CAPEX AND OPEX can be saved.
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Bronswerk was present on #ICCI2014 in Turkey last week. Energy efficiency is a big topic for the Turkish economy and society. This presentation is about improvement areas for energy efficiency. The 1st area is : Newbuilds : start at the design: reducing energy consumption of process equipment. The 2nd area is: Upgrading of Installation: High efficiency fans & pumps: increase plant capacity and efficiency. Interesting ROI case studies included. Enjoy reading and feel free to contact us!
APPLICATION OF HEAT INTEGRATION AND SEQUENCING IN THE DESIGN OF ENERGY EFFICI...Manish Sharma (LION)
Distillation is the most widely used separation technique. The downside of the technology is the high capital and energy cost. A small scale distillation comprises of feed to be separated in 3-4 products. With the application of heat integration and distillation sequencing, both CAPEX AND OPEX can be saved.
Icci 2014 Dynamic Heat Exchange Solutions - Energy ROI Treasure?BRONSWERK
Bronswerk was present on #ICCI2014 in Turkey last week. Energy efficiency is a big topic for the Turkish economy and society. This presentation is about improvement areas for energy efficiency. The 1st area is : Newbuilds : start at the design: reducing energy consumption of process equipment. The 2nd area is: Upgrading of Installation: High efficiency fans & pumps: increase plant capacity and efficiency. Interesting ROI case studies included. Enjoy reading and feel free to contact us!
Enabling the next generation of High Efficiency Engines.
Despite increasing popularity, engine “downsizing” does not delivery dramatic real-world fuel economy benefits. Downsized engines must be operated at higher loads, often into regions where spark retard and/or over fueling is used to control knock. Maximum engine output in SI engines is limited by knock (auto-ignition). Therefore, mitigation of knock is an enabler for aggressive downsizing AND increased performance.
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Pumps and Fans are energy consuming equipment that can be found in almost all Industries. Therefore, it is important to check if they are running efficiently. This presentation give an overview about energy saving opportunities in pump and fan equipment. It was prepared in the context of energy auditor training in Nepal in the context of GIZ/NEEP programme. For further information go to EEC webpage: http://eec-fncci.org/
Hi! This is Kalpak, a mechanical engineer and this is my project portfolio. Please do take a moment to go through my work! I am a masters graduate from Texas A&M University and am looking to work in the field of design and thermal engineering
Enabling the next generation of High Efficiency Engines.
Despite increasing popularity, engine “downsizing” does not delivery dramatic real-world fuel economy benefits. Downsized engines must be operated at higher loads, often into regions where spark retard and/or over fueling is used to control knock. Maximum engine output in SI engines is limited by knock (auto-ignition). Therefore, mitigation of knock is an enabler for aggressive downsizing AND increased performance.
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High flow, high atomization, gasoline direct injectors with advanced injector technology. These injectors utilize a proprietary kinetic particle break-up mechanism with patented nozzles to provide smaller droplet sizes, superior fuel atomization, accurate controllability, and shorter liquid lengths versus leading conventional injectors. More than three years of research and testing have demonstrated significant improvements in fuel delivery. Engine tests show higher heat release and faster burn rates than conventional air-shear fuel injection mechanisms, resulting in improved fuel efficiency and increases in power.
Presented at Engine Expo, Novi 2015
This GOx-Kerosene fuel injection system utilizes tangential holes to naturally swirl the propellant and optimize mixture ratios. This was conducted for USC's Liquid Propulsion Laboratory.
Improving Energy Efficiency of Pumps and Fanseecfncci
Pumps and Fans are energy consuming equipment that can be found in almost all Industries. Therefore, it is important to check if they are running efficiently. This presentation give an overview about energy saving opportunities in pump and fan equipment. It was prepared in the context of energy auditor training in Nepal in the context of GIZ/NEEP programme. For further information go to EEC webpage: http://eec-fncci.org/
Hi! This is Kalpak, a mechanical engineer and this is my project portfolio. Please do take a moment to go through my work! I am a masters graduate from Texas A&M University and am looking to work in the field of design and thermal engineering
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Application of Additive Manufacturing in Aerospace IndustryAbhijeet Agarwal
This Presentation based on the benefits and the advantage of the Additive Manufacturing in the world. There how it make this useful around the companies and other things
1. Chosen Cylinder Configuration from Research Designed Cylinder, Port Face and Port Block with CAD Software
1.0 Introduction/Aim
• The aim of this project was to create a teaching aid that would be a
useful tool for lecturers of Thermodynamics and Engineering Design
and Analysis.
• Testing of a physical model could help consolidate theory learned in
lectures and tutorials providing students with a better understanding of
the applications of what they have learned in the classroom.
• Stationary model steam engine with accompanying model car chassis.
• This was achieved through the following: - research, design,
manufacture, construction and testing of the model engine powered by
a pressurised vessel containing steam.
• Emphasis on safety through numerous steps
2.0 Design
• With different engine designs considered from research into different
configurations the engine was taken from the initial design stage .
• The most suitable design was chosen due to a variety of factors, eg. Cost
of Materials
• Engine components created using CAD software PTC Creo Parametric 2.0.
• The area using Pro Engineer proved to be most useful was collecting
dimensions for corresponding components disregarding then need for trial
and error when assembling components physically.
• Due to mix of bought in and designed components CAD software was key
in ensuring compatibility.
• Files created using CAD software were created with the intention that they
could be exported and made compatible with rapid prototyping and 3 axis
milling machines.
5.0 Results
• Construction of subassemblies including boiler with attachments, mounted
flywheel, connecting rod and crank a final assembly brought all parts
together as designed.
• CAD assemblies displayed dimensionally accurate model corresponding to
now fully constructed physical model.
• FEA Analysis of Boiler at working pressure validated boiler design and
material were fit for purpose.
4.0 Testing
• Variety of tests were carried out to prove that the fully constructed engine
was safe for its intended application environment.
• Testing was mainly focussed on the model brass boiler due to this
component being a pressurised vessel.
• Several procedures, including analytical calculations, static structural FEA
Analysis and physical testing were carried out to ensure its validity.
• Using these 3 methods, the boiler was tested to working pressure and to a
factor of safety of 3 of the working pressure.
• Boiler was subjected to hydraulic pressure tests conforming with British
Standard BS ISO 16528-1:2007
• Outcome of testing of various heat sources resulted in use of solid fuel.
• Fully constructed model was tested with compressed air to amend problems
with piston and crank synchronisation.
• Risk Assessments for use of naked flame and pressurised vessel in workshop.
Component Material Manufacturing
Process
Flywheel Aluminium 6082 3 Axis Machining
Piston & Cylinder Brass Die Casting/Lathe
Firebox Stainless Steel (SS) Fabrication
Chassis Stainless Steel (SS) Fabrication
Flywheel Mount Tricyclodecane
Diemethanol Dicrylate
Rapid Prototyping
Axle Flywheel Tricyclodecane
Diemethanol Dicrylate
Rapid Prototyping
Crank Tricyclodecane
Diemethanol Dicrylate
Rapid Prototyping
3.0 Manufacture
• There were a number of
manufacturing methods
exploited throughout the
construction of this model
steam engine.
• Parts chosen to be 3-Axis
machined were parts that
needed to be hard wearing
and of a suitable design as
to be compatible with the
machining process.
• Components picked for manufacturing through this method were chosen under
the assumption they were unlikely to be under large amounts of stress or high
temperatures.
• Fabrication was also used to create several components made from sheet metal
Internal
Pressure
Equivalent
Stress
(MPa)
Total
Deformation
(mm)
Fit for
Purpose
(Y/N)
15psi 10.468 3.8379e-3 Y
45psi 31.404 0.011514 Y
Ignition Temp Testing Solid Fuel with Infrared Camera Static Structural FEA Pressure Testing at Working Pressure (15psi)
Crank Position v Piston/Cylinder Position
6.0 Conclusions/Recommendations
• With design , manufacture, construction and testing completed it can be
concluded this model steam engine would be valuable as a teaching aid.
• With regards to recommendations researched for teaching applications ,
further work would be required with regards to construction of lesson plans.
• Further work that could complement this project could include :
1. Increasing boiler efficiency
2. Convection analysis using FEA software
3. Manufacture of all components
4. Inclusion of electronics
5. Closed system.
• Boiler was heated and steam
created allowed the engine to
run smoothly.
• Engine when run at designed
working pressure performed as
intended.
Acknowledgments
David Ross, Ian Hamilton, Colin Dalglish, Derek Leitch, Colin Russell
3 Axis Machining Process of Top Side of Flywheel D Rapid Prototyping of Flywheel Mount
Completed CAD Assembly of Model Steam Engine Successful Running of Steam Engine in Stationary Mode