This document summarizes a steady state thermal analysis of fins on a single cylinder internal combustion engine. The analysis evaluated different fin geometries (curved vs rectangular), materials (grey cast iron, aluminum alloy 6061, aluminum alloy 6060), and their impact on surface temperature and heat flux through natural convection cooling over 10 seconds. The results showed that rectangular fins made of aluminum alloy 6060 achieved the highest average temperature of 294.34°C and heat flux of 139071 W/m2, making it the most efficient configuration for cooling the engine.
Welding is a fabrication process that joins materials, usually metals or thermoplastics, by using high heat to melt the parts together and allowing them to cool, causing fusion. Welding is distinct from lower temperature metal-joining techniques such as brazing and soldering, which do not melt the base metal.
One of the welding processes that used in Engineering field is the pressure gas welding. There are several types of welding processes similar to this, but pressure gas welding has its unique features.
Thanks for the colleagues who give this slides to publish.
Welding is a fabrication process that joins materials, usually metals or thermoplastics, by using high heat to melt the parts together and allowing them to cool, causing fusion. Welding is distinct from lower temperature metal-joining techniques such as brazing and soldering, which do not melt the base metal.
One of the welding processes that used in Engineering field is the pressure gas welding. There are several types of welding processes similar to this, but pressure gas welding has its unique features.
Thanks for the colleagues who give this slides to publish.
Finite Element Simulation of Plasma Transferred ARC Welding [PTAW] of Structu...IJERA Editor
Plasma transferred Arc welding is one of the most widely used welding process, in which the metals are fused just above the melting point, and makes the metal to fuse. It is employed in many applications like tool die and metal casting, strip metal welding etc. This investigation is to analyze temperature distribution residual stress and distortion by varying the heat source parameter in SYSWELD, and compared the results with ANSYS. The simulation of Plasma Transferred Arc welding was of structural steel plate performed using a non-linear transient heat transfer analysis. Heat losses due to convection and variation of material properties with temperature were considered in this analysis. To incorporate the heat developed the Gaussian distribution was considered. Finite element simulations were performed using ANSYS Parametric Design Language (APDL) code and using SYSWELD. The temperatures obtained were compared with experimental results for validation. It was found that the predicted values of temperature agree very well with the experimental values. Residual Stress and Distortion were also predicted for various heat Input. The effect of heat input on residual stress and distortion was investigated.
Modeling of the Heating Sequences of Lightweight Steel/Aluminum Bimaterial Bi...Fluxtrol Inc.
Paper by:
Robert Goldstein Fluxtrol Inc., Auburn Hills, MI, USA
Bulent Chavdar Eaton, Southfield, MI, USA
Lynn Ferguson DANTE Solutions Inc., Cleveland, OH, USA
ABSTRACT:
In this paper, the concept studied is hot forged from a bimetal
billet, which is a steel tube press fit with a solid aluminum
core and welded shut with steel end caps. For the experimental
part of the studies Al 7075 was selected as the core material
due to its high strength to weight ratio and 1020 steel was
selected because of its availability as a tube. Induction heating
was selected as the heating method for bimetal forging. This
is due to the ability of induction heating to rapidly heat the
steel layer. Successful bimetal forging of a closed vessel
requires the steel layer to be in the austenite phase prior to the
aluminum reaching high temperatures to prevent
compromising the weld seams. Modeling of the induction
heating process is complex due to the dimensional movement
of components during the process. A method was developed
to accurately model the induction heating process and predict
power requirements. The method will be described and the
results of the models will be compared to experimental
findings. The forming process will be discussed in another
paper at the conference. The simulation presented is for solid
state forging of a steel aluminum billet, but the method for
modeling the process is the same for hot hydroforging or other
material combinations.
The physical principle of the electric arc furnace will be briefly explained. It will be made clear how latest context and technology bound developments triggered the breakthrough of the electric arc furnace as a future oriented technology. The increasing relevance of the electric arc furnace will be illustrated by some examples coming from a broad range of industrial sectors. Some indications will be given on the impact of the electric arc furnace on the electrical system.
Based on overall economic figures, indications will be given of the chance for further penetration of the electric arc furnace in industrial thermal processes.
Recognizing and Eliminating Flux Concentrator FailuresFluxtrol Inc.
http://fluxtrol.com
Overview:
• What are the failure modes of a flux concentrator?
• How do we improve the design to prevent the failure in the future?
• Examples of coil lifetime improvement by proper use of flux
concentrators.
FIN has a team of specialised engineers and technicians who are capable of designing automated machines to fit your needs. We are also able to modify existing machines, do repairs and programming as well as scheduled maintenance. Our experienced team is ready to help you to increase productivity whilst improving efficiency.
Finite Element Simulation of Plasma Transferred ARC Welding [PTAW] of Structu...IJERA Editor
Plasma transferred Arc welding is one of the most widely used welding process, in which the metals are fused just above the melting point, and makes the metal to fuse. It is employed in many applications like tool die and metal casting, strip metal welding etc. This investigation is to analyze temperature distribution residual stress and distortion by varying the heat source parameter in SYSWELD, and compared the results with ANSYS. The simulation of Plasma Transferred Arc welding was of structural steel plate performed using a non-linear transient heat transfer analysis. Heat losses due to convection and variation of material properties with temperature were considered in this analysis. To incorporate the heat developed the Gaussian distribution was considered. Finite element simulations were performed using ANSYS Parametric Design Language (APDL) code and using SYSWELD. The temperatures obtained were compared with experimental results for validation. It was found that the predicted values of temperature agree very well with the experimental values. Residual Stress and Distortion were also predicted for various heat Input. The effect of heat input on residual stress and distortion was investigated.
Modeling of the Heating Sequences of Lightweight Steel/Aluminum Bimaterial Bi...Fluxtrol Inc.
Paper by:
Robert Goldstein Fluxtrol Inc., Auburn Hills, MI, USA
Bulent Chavdar Eaton, Southfield, MI, USA
Lynn Ferguson DANTE Solutions Inc., Cleveland, OH, USA
ABSTRACT:
In this paper, the concept studied is hot forged from a bimetal
billet, which is a steel tube press fit with a solid aluminum
core and welded shut with steel end caps. For the experimental
part of the studies Al 7075 was selected as the core material
due to its high strength to weight ratio and 1020 steel was
selected because of its availability as a tube. Induction heating
was selected as the heating method for bimetal forging. This
is due to the ability of induction heating to rapidly heat the
steel layer. Successful bimetal forging of a closed vessel
requires the steel layer to be in the austenite phase prior to the
aluminum reaching high temperatures to prevent
compromising the weld seams. Modeling of the induction
heating process is complex due to the dimensional movement
of components during the process. A method was developed
to accurately model the induction heating process and predict
power requirements. The method will be described and the
results of the models will be compared to experimental
findings. The forming process will be discussed in another
paper at the conference. The simulation presented is for solid
state forging of a steel aluminum billet, but the method for
modeling the process is the same for hot hydroforging or other
material combinations.
The physical principle of the electric arc furnace will be briefly explained. It will be made clear how latest context and technology bound developments triggered the breakthrough of the electric arc furnace as a future oriented technology. The increasing relevance of the electric arc furnace will be illustrated by some examples coming from a broad range of industrial sectors. Some indications will be given on the impact of the electric arc furnace on the electrical system.
Based on overall economic figures, indications will be given of the chance for further penetration of the electric arc furnace in industrial thermal processes.
Recognizing and Eliminating Flux Concentrator FailuresFluxtrol Inc.
http://fluxtrol.com
Overview:
• What are the failure modes of a flux concentrator?
• How do we improve the design to prevent the failure in the future?
• Examples of coil lifetime improvement by proper use of flux
concentrators.
FIN has a team of specialised engineers and technicians who are capable of designing automated machines to fit your needs. We are also able to modify existing machines, do repairs and programming as well as scheduled maintenance. Our experienced team is ready to help you to increase productivity whilst improving efficiency.
Heat transfer from extended surfaces (or fins)tmuliya
This file contains slides on Heat Transfer from Extended Surfaces (FINS). The slides were prepared while teaching Heat Transfer course to the M.Tech. students in Mechanical Engineering Dept. of St. Joseph Engineering College, Vamanjoor, Mangalore, India.
Contents: Governing differential eqn – different boundary conditions – temp. distribution and heat transfer rate for: infinitely long fin, fin with insulated end, fin losing heat from its end, and fin with specified temperatures at its ends – performance of fins - ‘fin efficiency’ and ‘fin effectiveness’ – fins of non-uniform cross-section- thermal resistance and total surface efficiency of fins – estimation of error in temperature measurement - Problems
Investigation of Heat Dissipation in Petrol Engine Cylinder during Explosion ...IJARTES
The current work determines the rate of heat flow
from an engine cylinder. The heat addition during the heat
addition stage or during explosion is determined by using the
classical equations. The heat dissipation from the cylinder is
enhanced by the fins provided around the cylinder. The results
which are obtained are validated with the finite element
analysis software ANSYS APDL. A study is conducted by
considering various materials to obtain optimum material
selection to enhance the better flow of heat from the system.
Thermal reliability faces critical challenges from emerging FinFET-based designs. As designs transition from planar MOS to FinFET transistors, current density increases by 25% and that combined with lower thermal conductivity substrate and 3-D narrow fin structure, local heat gets trapped resulting in thermal-aware EM issues. This presentation introduces Sentinel-TI™, a thermal integrity platform and demonstrates how Chip Thermal Model (CTM™) based power-thermal convergence and interconnect-driven methodology help address the thermal reliability challenges associated with these design. Learn more on our website: https://bit.ly/1sh7I8p, https://bit.ly/1CW3FRT, https://bit.ly/1qk5Juj and (https://bit.ly/1rtrGat)
The smart ring called ”Fin” promises to be the next revolution in wearable technology. A young Indian techie has invented a ring-type device, that can turn your palm into a gesture interface to control multiple devices, including mobile phones, television, music system, gaming console to name a few.
Engine Block/Cylinder Block is the structure which contains the cylinders, and other parts, of an internal combustion engine. In an early automotive engine, the engine block consisted of just the cylinder block, to which a separate crankcase was attached. Engine block is affected by pressure and the thermal conditions happen inside the engine. So we come up with static structural and transient thermal analysis on the engine block. This report provides Stress, Strain and Total Deformation of Engine due to Pressure, Temperature and Heat Flux. We come up with the fatigue life of the Engine Block due to different loading conditions.
A cylinder block is an integrated structure comprising the cylinder(s) of a reciprocating engine and often some or all of their associated surrounding structures. The term engine block is often used synonymously with "cylinder block" The analysis of the combustion chamber is done by using different materials. By conducting the above analysis on the combustion chamber combustion rate, pressure and temperature gradient conditions are found and the best material for the combustion chamber is suggested.
Thermal analysis is conducted to find heat dissipation rate in engine block with the variation of materials Structural and fatigue analysis (dynamic) is conduct on engine block at working load conditions to evaluate and compare stress, strain, deformation and fatigue life with the variation of materials.
Frequency analysis is conducted on engine block with the variation of materials to evaluate frequency, Using these values material selection will be done, the value should be nearby previous one (cast iron) maximum accepted variation value 65HZ.
Remaining life assessment of refinery furnace tubes using finite element methodBarhm Mohamad
Crude oil heater 9Cre-1Mo steel tubes from a refinery plant were studied, after 5 years of service at nominally 650 Cº and 3 bar, to predict their remnant lives. The investigation included dimensional, hardness and tensile measurements in addition to accelerated stress rupture tests between 650 Cº and 700 Cº and microstructural examination. Tube specimens were taken from two sections, the overheated side and the side which only saw the nominal operating temperature. The method employed involved the prediction of the increase in temperature with increasing sediment deposition during the operating life times using an FEM model. In addition the predicted temperatures are used to derive appropriate creep properties at relevant temperatures in a 3D pipe FEM creep analysis to predict the pipe deformation rate. All compare well with the actual service exposed pipe measurements and layer deposition. The overheated side revealed a small loss of creep strength in a stress rupture test. A layer of sediment (appr. 10 mm thickness) consisting basically of sintered carbon (coke) spread over the inside of the tube was acting as a thermal barrier causing the temperature to rise above 650 Cº. Analysis for the overheated side predicted an upper bound temperature of 800 Cº and a life of about 50 h suggesting that failure by creep rupture could occur rapidly in the sediment region.
STUDY OF MICRO STRUCTURE OF HEAT TREADTED EN8 STEEL Anis Haider
EN8 is a very popular grade of through-hardening medium carbon steel, which is readily machined able in any condition. EN8 is suitable for the manufacture of parts such as general-purpose axles and shafts, gears, bolts and studs
Enhancement of Heat Transfer Analysis and Optimization of Engine Fins of Vary...ijtsrd
The Engine cylinder is one of the major automobile components, which is subjected to high temperature variations and thermal stresses. In order to cool the cylinder, fins are provided on the cylinder to increase the rate of heat transfer. By doing thermal analysis on the engine cylinder fins, it is helpful to know the heat dissipation inside the cylinder. The principle implemented in this project is to increase the heat dissipation rate by using the invisible working fluid, nothing but air. As know, by increasing the surface area we can increase the heat dissipation rate, so designing such a large complex engine is very difficult. The main purpose of using these cooling fins is to cool the engine cylinder by air. The main aim of the project is to analyse the thermal properties by varying geometry, material, distance between the fins and thickness of cylinder fins. Parametric models of cylinder with fins have been developed to predict the transient thermal behaviour. The models are created by varying the geometry circular and also by varying thickness of the fins for both geometries. The 3D modelling software used is Pro/Engineer. Thermal analysis is done on the cylinder fins to determine variation temperature distribution over time. The analysis is done using ANSYS. Thermal analysis determines temperatures and other thermal quantities. In this thesis, using materials cast iron, Copper and Aluminium alloy 6082 are also for cylinder fin body. Thermal analysis is done using all the three materials by changing geometries, distance between the fins and thickness of the fins for the actual model of the cylinder fin body. K. Karthikeyan | C. Saravanan | Dr. T. Senthil Kumar"Enhancement of Heat Transfer Analysis and Optimization of Engine Fins of Varying Geometry" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-2 | Issue-4 , June 2018, URL: http://www.ijtsrd.com/papers/ijtsrd14327.pdf http://www.ijtsrd.com/engineering/mechanical-engineering/14327/enhancement-of-heat-transfer-analysis-and-optimization-of-engine-fins-of-varying-geometry/k-karthikeyan
Effect of Heat Treatment on Corrosion Behavior of Spring SteelsEditor IJCATR
The experimental work deals with the effect of heat treatment on the corrosion behaviour of spring steels. In this study the
heat treatments like hardening, normalizing and tempering were done for spring steels to obtain martensitic matrix, pearlitic structure
and tempered martensitic matrix respectively. After heat treatment the microstructural studies were carried out for the samples using
SEM. Hardness measurements were done. The corrosion behaviour of all heat treated samples in HCl at different concentration (1.5N,
2N and 2.5N) was determined using Tafel extrapolation technique. The variation in the corrosion rates due to the effect of heat
treatment was noted. The results indicate that for fully martensitic matrix the corrosion rate is minimum and for pearlitic structure its
maximum. As tempering time is increased the corrosion rate increases correspondingly. The corroded microstructural images were
also taken using SEM and analysed.
Heat Transfer Analysis and Optimization of Engine Cylinder Fins of Varying Ge...IOSR Journals
: The main aim of the project is to analyze the thermal properties by varying geometry, material and
thickness of cylinder fins. Parametric models of cylinder with fins have been developed to predict the transient
thermal behavior. The models are created by varying the geometry, rectangular, circular and curved shaped
fins and also by varying thickness of the fins. The 3D modeling software used is Pro/Engineer.The analysis is
done using ANSYS. Presently Material used for manufacturing cylinder fin body is Aluminum Alloy 204 which
has thermal conductivity of 110-150W/mk. We are analyzing the cylinder fins using this material and also using
Aluminum alloy 6061 and Magnesium alloy which have higher thermal conductivities.
Design and Fabrication of Crucible Furnaces by using Black Smithy SetupDr. Amarjeet Singh
The main aim was, to design Pit Furnace from the
setup of black smithy. As the Smithy setup was not in use so it
is converted into Pit Furnace setup. The purpose of using Pit
Furnace is to melt nonferrous material. The Nonferrous
materials such as Aluminum, Aluminum alloy, Copper, Brass,
etc. The Aluminum has less melting point (680ᵒ C, 1218ᵒF) and
cheaper than other. The thermal efficiency of furnace is
13.72% which is obtained by melting 2 kg of Aluminum for 75
minutes. Normally thermal of pit furnace is between 4-19%.
The blower is used to supply the air into the furnace chamber
to burn the coal. For melting the Aluminum, Crucible should
sustain higher temperature so Graphite Crucible is used. This
Crucible has thinner wall and have more refractory
properties.
Reduction of cold start emissions in automotive catalytic converter using the...Asheesh Padiyar
Catalytic converters are used to convert harmful exhaust gases like CO, NOx and unburnt hydrocarbons released by
internal combustion engine of automobiles into less harmful gases like CO2, H2O and N2. During the start-up of engine run, catalytic converters suffer cold start problems as the catalyst does not remain active in cold conditions. This results in emission of unconverted harmful gases into the atmosphere. This work attempts to eliminate cold start problems using a heat storage system to keep the catalytic converter hot even under engine off conditions. A eutectic alloy of Mg-Zn-Al is used as the Phase Change Material (PCM) to store the heat around the catalyst. This alloy has high latent heat of fusion, high specific heat, suitable melting point and high thermal stability. Mg-Zn-Al eutectic alloy changes its state between liquid and solid on application and removal of heat. Thus this phase change material acts as a heat storage mechanism in the catalytic converter. Catalytic converter design also involves Rockwool insulation in order to aid longer heat storage. This thermal energy storage system as a combination of PCM and insulation, keeps the catalytic converter hot for several hours even after the engine is shut of
STUDY ON PREDICTION OF MECHANICAL PROPERTIES OF LARGE RING-SHAPED FORGING DEP...IAEME Publication
Large ring-shaped forgings manufactured by ring rolling, as heavy as 10 tons, are greatly affected by cooling. In the present study, controlled cooling was performed to improve the mechanical properties of large ring-shaped forgings. To quantify cooling rate, thermocouples were used to measure the cooling rate and the microstructures of the products were observed during still air cooling, fan cooling, mist control cooling, and water quenching. The temperature distribution measured in the four cooling methods was used to calculate the heat transfer coefficient in each cooling method by the inverse method. The mechanical properties were tested with specimens obtained from the test block for each cooling method, and continuous cooling transformation (CCT) curves were obtained by using measured microstructure contents. The mechanical properties of the regions corresponding to the regions of the specimens were calculated on the basis of the CCT curves and the heat transfer coefficients. The experimental values and the analytical values of the strength of the products manufactured by each cooling method were compared to verify that the mechanical properties at each region of the products depending on the cooling methods may be predicted
Increasing Inductor Lifetime by Predicting Coil Copper Temperatures PresentationFluxtrol Inc.
In recent years, there has been a significant increase in the customer demands for improved induction coil lifetime. This has led to several publications in recent years by induction tooling manufacturers [1-4]. The main conclusion in these papers is that besides mechanical crashes the cause of most induction coil failures is localized overheating of the coil copper due to insufficient cooling.
What is lacking from these publications is any way to determine what is sufficient cooling. In this paper, a scientific method for determining local copper temperatures will be presented. This will include evaluations of heat transfer coefficients for different sections of a multi-component inductor, dependence of heat transfer coefficient on water pressure and water passage cross-section, non-uniform power density distributions in various 2-D cross-sections and the resulting temperature distribution in the copper winding. The effects of duty cycle on optimal design will also be considered.
International Journal of Engineering and Science Invention (IJESI) is an international journal intended for professionals and researchers in all fields of computer science and electronics. IJESI publishes research articles and reviews within the whole field Engineering Science and Technology, new teaching methods, assessment, validation and the impact of new technologies and it will continue to provide information on the latest trends and developments in this ever-expanding subject. The publications of papers are selected through double peer reviewed to ensure originality, relevance, and readability. The articles published in our journal can be accessed online.
Several measurements were made to study temperature and chemical distribution inside a molten bath in a Tower Type & Reverberatory Type furnace. The furnace was an Aluminium scrap melting furnace and it was equipped with the “TSIT” which is Electromagnetic induction stirring of molten metal. The molten metal used for the experiment was an Al-Si alloy. There were 4 bath thermocouples installed inside the furnace which were used for measuring of the bath temperature in different places and depths of the bath. One more thermocouple measured temperature of the furnace roof. There were 3 different places chosen for taking samples to make chemical analysis. The data from the five thermocouples and the result of the chemical analysis of the 3 samples were compared and analyzed. The results show how the TSIT makes temperature and chemical homogeneity of the entire molten bath in a Reverberatory furnace during different technological operations.
Steady state thermal analysis of a 4-stroke single
1. Steady state thermal analysis of a 4-stroke
single cylinder I.C.E fins
Varun Bhalerao
Dr. Ali Ogut
KGCOE - Department of Mechanical Engineering
Rochester Institute of Technology
12/25/2016 Rochester Institute of Technology 1
2. Introduction
• Temperature inside the
combustion chamber goes up to
1500°C
• Metal temperature needs to be
brought down to ensure good
efficiency
• High temperature burns the oil
inside the cylinder
• Decreases the efficiency and
lowers the lifespan of the engine
• Fins are an efficient way of
cooling along with a heat
exchanger
12/25/2016 Rochester Institute of Technology 2
Figure 1: Failure of the piston due to high temperature
3. Objective
Most efficient combination of material and
fin geometry by performing thermal
analysis of fins having natural convection
cooling:
• Analysis of curved and rectangular fins
for the surface temperature and heat
flux
• Compare different fin materials
• Grey cast iron
• Aluminium alloy 6061
• Aluminium alloy 6060
• Curved fins: 37 mm length and 12 mm
radius
• Rectangular fins: 57.8 mm * 60.8 mm
• Thickness of fins: 1.5 mm
12/25/2016 Rochester Institute of Technology 3
Figure 2: Rectangular fins Figure 3: Curved fins
Table 1: Material properties
4. Mesh
• The lowest element size that was
accepted: 0.001
• Tested various meshes
• Coarse and fine mesh for an
element size of 0.002
• Coarse and fine mesh for an
element size of 0.001
• The temperature and heat flux
for every fin remained same for
every mesh
• Mesh independence was
observed
12/25/2016 Rochester Institute of Technology 4
Figure 4: Coarse mesh (0.002 element size)
Figure 5: Fine mesh (0.001 element size)
5. Analysis
• In steady state system, defined
the temperature of 300°C in the
combustion chamber
• Set the ambient temperature to
22°C
• Allowed the system to go under
natural convection cooling for 10
seconds
• Calculated the average
temperature and the heat flux
for various combinations of fins
for the 2 geometries and 3
materials used
12/25/2016 Rochester Institute of Technology 5
Figure 6 and 7: Temperature and heat flux distribution for curved fins (Aluminium alloy 6061)
Figure 8 and 9: Temperature and heat flux distribution for rectangular fins (Aluminium alloy 6061)
6. Conclusion
• Heat transfer rate of the rectangular fins is
higher than the curved fins in natural
convection
• For rectangular fins, Aluminium alloy 6060 has
the highest average temperature (294.34 °C)
and heat flux (139071.1818 W/m2)
• For curved fins, Aluminium alloy 6060 has the
highest average temperature (293.21 °C) and
heat flux (128858.5 W/m2)
• The rectangular configuration with the
Aluminium alloy 6060 for fins is the most
efficient configuration
• For rectangular and curved fins, Aluminium
alloy 6060 is the most efficient and grey cast
iron is the least efficient.
12/25/2016 Rochester Institute of Technology 6
265
270
275
280
285
290
295
Temperature(°C)
Average surface temperature of
curved fins for different materials
Grey Cast Iron Aluminium Alloy 6061 Aluminium Alloy 6060
105000
110000
115000
120000
125000
130000
Heatflux(W/sq.m)
Average heat flux of curved fins for
different materials
Grey Cast Iron Aluminium Alloy 6061 Aluminium Alloy 6060
115000
120000
125000
130000
135000
140000
145000
Heatflux(W/sq.m)
Average heat flux for rectangular fins
for different materials
Grey cast iron Aluminium alloy 6061 Aluminium alloy 6060
265
270
275
280
285
290
295
Temperature(°C)
Average surface temperature for
rectangular fins for different
materials
Grey cast iron Aluminium alloy 6061 Aluminium alloy 6060
