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1 – 10 of 496Mohd Nor Azam Mohd Dali, Jaharah A. Ghani, Che Hassan Che Haron and Sharudin Hassan
The purpose of this paper is to produce dimple structure on a cylindrical surface for Aluminium-Silicon (Al-Si) alloy piston (A390) using turning process. The process selection is…
Abstract
Purpose
The purpose of this paper is to produce dimple structure on a cylindrical surface for Aluminium-Silicon (Al-Si) alloy piston (A390) using turning process. The process selection is based on factors such as the capability of machining process, low cost process, minimum set up time and green working environment.
Design/methodology/approach
Three main machining parameters that greatly influenced the dimple structure fabrication were identified from previous researches (cutting parameters, vibration and cutting tool geometry). To facilitate dimple structure fabrication using turning process, a dynamic assisted tooling (DATT) was developed. Experiments were conducted on Al-Si A390 material for future application of automotive piston. A three-dimensional surface profiler (Alicona) was used for geometry measurement and analysis of dimple structure. The Taguchi method, with an L8 orthogonal array, was used to accommodate seven parameters used in the fabrication of dimpled structures using turning process. Signal-to-noise (S/N) ratio and observation on the shape of dimple structure array were used to determine the optimum machining condition.
Findings
Optimum parameters obtained using S/N ratio analysis were cutting speed of 9 m/min, depth of cut of 0.01 mm, amplitude displacement of 1 mm, nose radius of 0.4 mm and frequency of (25 Hertz). Whereas feed rate, rake and relief angles were not significant to the size, shape and dimple array; therefore, their selected values depend on requirement of the application. Based on the S/N ratio and uniformity of the array of dimple structure as the main reference, the sixth and eighth experiment conditions almost achieved the optimum condition which are able to produce the width of dimple structure of 396.82 and 560.43 μm, respectively, dimple length of 3,261.6 and 2,422.7 μm, respectively, dimple depth of 63.43 and 65.97 μm, respectively, area ratio of 10 and 10.39 per cent, respectively, and surface roughness of 3.0023 and 3.0054 μm, respectively. These results are within the range of dimple structure obtained by the previous researchers for sliding mechanical components application.
Originality/value
The optimum condition of machining parameters in producing uniform dimple structure led to the compilation of data base in dimple structure research via turning process. Dimple structure produced is similarly obtained with other processes like laser, burnishing, photochemical, etc. DATT developed has the ability to produce repeatable vibration frequency, stable and consistent amplitude displacement using a simple crank concept and structure that can be mounted on all types of lathe machine either conventional or computer numerical control.
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Lei Luo, Wei Du, Songtao Wang, Weilong Wu and Xinghong Zhang
The purpose of this paper is to investigate the optimal geometry parameters in a dimple/protrusion-pin finned channel with high thermal performance.
Abstract
Purpose
The purpose of this paper is to investigate the optimal geometry parameters in a dimple/protrusion-pin finned channel with high thermal performance.
Design/methodology/approach
The BSL turbulence model is used to calculate the flow structure and heat transfer in a dimple/protrusion-pin finned channel. The optimization algorithm is set as Non-dominated Sorting Genetic Algorithm II (NSGA-II). The high Nusselt number and low friction factor are chosen as the optimization objectives. The pin fin diameter, dimple/protrusion diameter, dimple/protrusion location and dimple/protrusion depth are applied as the optimization variables. An in-house code is used to generate the geometry model and mesh. The commercial software Isight is used to perform the optimization process.
Findings
The results show that the Nusselt number and friction factor are sensitive to the geometry parameters. In a pin finned channel with a dimple, the Nusselt number is high at the rear part of the dimple, while it is low at the upstream of the dimple. A high dissipative function is found near the pin fin. In the protrusion channel, the Nusselt number is high at the leading edge of the protrusion. In addition, the protrusion induces a high pressure drop compared to the dimpled channel.
Originality/value
The originality of this paper is to optimize the geometry parameters in a pin finned channel with dimple/protrusion. This is good application for the heat transfer enhancement at the trailing side for the gas turbine.
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Faarih Farhan Mohd Nasir, Jaharah A. Ghani, Mohd Shahir Kasim and Wan Fathul Hakim W. Zamri
This research aims to present the characteristics of dimple structure which was fabricated using a turning machine, where the characteristics include sizes, shapes, area ratio and…
Abstract
Purpose
This research aims to present the characteristics of dimple structure which was fabricated using a turning machine, where the characteristics include sizes, shapes, area ratio and aspect ratio. This research aims at filling the gap in the machining parameters of previous research in producing dimple by using turning process with the aid of dynamic assisted tooling for turning (DATT). In producing dimple, a carbide insert grade H1 was used on a hypereutectic aluminium silicon alloy (A390) material. Dimple has many advantages such as for reducing friction coefficient, load-carrying capacity and trap wear debris for sliding mechanical components.
Design/methodology/approach
There are seven machining parameters (cutting speed, feed rate, depth of cut, frequency, amplitude, rake angle, relief angle and nose radius) which have an influence on dimple produced. Taguchi method (orthogonal arrays L8) was used to conduct the experiment systematically and efficiently for these seven parameters. A carbide insert grade H1 was used as a cutting tool on a turning machine with the aid of DATT. The dimple structure was fabricated on a cylindrical rod hypereutectic aluminium silicon alloy (A390). A profilometer 3D Alicona infinite focus and an optical microscope equipped with Vis software were used to analyse the fabricated dimple structure.
Findings
Various shapes and sizes of ellipse dimples were produced in this research, including short and long drops with lengths in the range of 517.03–3,927.61 µm, widths of 565.15–1,039.19 µm, depths of 14.46–124.87 µm, area ratios of 5.05–25.65% and aspect ratios of 0.007%–0.111%. There were four experiments within the optimal area ratio range of 10%–20%, i.e. the second, third, seventh and eighth experiments. The width of these dimples was 895.95, 961.39, 787.27 and 829.22 µm, length was 826.26, 3163.13, 885.98 and 1026.65 µm, depth was 83.67, 84.19, 87.05 and 110.70 µm and area ratio was 15.12%, 13.14%, 14.79% and 12.70%. The surface roughness of textured surface was below 1 µm. In this research, the results obtained were similar with that of previous researchers on dimple structure related to tribology performance.
Originality/value
There exists machining parameters, namely, cutting speed and frequency, that were not used by previous research in producing dimple. These machining parameters (cutting speed and frequency) were used in this research to produce dimple via turning process with the aid of DATT using carbide insert grade H1. The turning process is an environmentally friendly process which is suitable for mass production for fabricating dimple structure as compared to most of the current methods which are widely used in fabricating dimple structure.
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Chenchun Shi, Aibing Yu, Jianzhao Wu, Weiyang Niu and Yanlin Wang
The study aims to compare tribological properties between laser dimple textured surface and drilled dimple textured surface, and to analyze the influence of dimple hardened edges…
Abstract
Purpose
The study aims to compare tribological properties between laser dimple textured surface and drilled dimple textured surface, and to analyze the influence of dimple hardened edges and ability of trapping wear debris on wear properties of dimple textured surfaces.
Design/methodology/approach
Circular textured dimples were produced on AISI 1,045 specimen surfaces using laser surface texturing (LST) and drilled surface texturing (DST) methods. Tribological behaviors of LST, DST and non-textured specimens were studied using ball-on-disc tribo-tester. Metallographic structures, dimples and worn surface morphologies were observed using a three-dimensional digital microscope. Hardnesses of substrate and dimple edges were measured.
Findings
There was no obvious difference in wear and friction coefficients between LST and DST specimens. Hardnesses of laser dimple edges were much higher than that of drilled dimple edges and specimen substrate. The hardened materials of laser dimple edge included recast zone and heat affect zone. Laser dimple was cone-shaped and drilled dimple was cylinder-shaped. Drilled dimple had a better ability of trapping wear debris than laser dimple. Non-uniform wear phenomenon occurred on worn surfaces of LST dimple specimens.
Originality/value
The ability of textured dimples to trap wear debris is affected by single dimple volume. Hardened edges of dimples cause non-uniform wear on worn surfaces of LST specimens.
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Mohammad Fazli and Mehrdad Raisee
This paper aims to predict turbulent flow and heat transfer through different channels with periodic dimple/protrusion walls. More specifically, the performance of various low-Re k…
Abstract
Purpose
This paper aims to predict turbulent flow and heat transfer through different channels with periodic dimple/protrusion walls. More specifically, the performance of various low-Re k-ε turbulence models in prediction of local heat transfer coefficient is evaluated.
Design/methodology/approach
Three low-Re number k-ε turbulence models (the zonal k-ε, the linear k-ε and the nonlinear k-ε) are used. Computations are performed for three geometries, namely, a channel with a single dimpled wall, a channel with double dimpled walls and a channel with a single dimple/protrusion wall. The predictions are obtained using an in house finite volume code.
Findings
The numerical predictions indicate that the nonlinear k-ε model predicts a larger recirculation bubble inside the dimple with stronger impingement and upwash flow than the zonal and linear k-ε models. The heat transfer results show that the zonal k-ε model returns weak thermal predictions in all test cases in comparison to other turbulence models. Use of the linear k-ε model leads to improvement in heat transfer predictions inside the dimples and their back rim. However, the most accurate thermal predictions are obtained via the nonlinear k-ε model. As expected, the replacement of the algebraic length-scale correction term with the differential version improves the heat transfer predictions of both linear and nonlinear k-ε models.
Originality/value
The most reliable turbulence model of the current study (i.e. nonlinear k-ε model) may be used for design and optimization of various thermal systems using dimples for heat transfer enhancement (e.g. heat exchangers and internal cooling system of gas turbine blades).
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Jin-yuan Qian, Zan Wu, Qian-Kun Zhang, Zhi-Jiang Jin and Bengt Ake Sunden
The purpose of this paper is to study the effects of dimple geometries and arrangements on the heat transfer enhancement in a dimple jacketed heat exchanger.
Abstract
Purpose
The purpose of this paper is to study the effects of dimple geometries and arrangements on the heat transfer enhancement in a dimple jacketed heat exchanger.
Design/methodology/approach
For the purpose of this paper, with the experimental validated numerical model, this paper carries out numerical simulations of both single dimples with different geometries and the whole dimple jacketed heat exchanger with different dimple arrangements. For a single dimple, its secondary vortex flow, temperature differences and the pressure drop performance for different geometries are analyzed. For the whole dimple jacketed heat exchanger, the heat transfer and pressure drop performances are investigated by comparing the no dimple, triangular and rectangular dimple arrangements.
Findings
Results show that dimples can improve the heat transfer efficiency compared with conventional jacketed heat exchanger, and specific geometries and arrangement of dimples for better heat transfer performance are figured out.
Originality/value
This paper considers both dimple geometries and arrangements, which can be useful for further applications in specific integrated devices or similar applications.
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Jian Liu, Gongnan Xie, Bengt Ake Sunden, Lei Wang and Martin Andersson
The purpose of this paper is to augment heat transfer rates of traditional rib-elements with minimal pressure drop penalties.
Abstract
Purpose
The purpose of this paper is to augment heat transfer rates of traditional rib-elements with minimal pressure drop penalties.
Design/methodology/approach
The novel geometries in the present research are conventional cylindrical ribs with rounded transitions to the adjacent flat surfaces and with modifications at their bases. All turbulent fluid flow and heat transfer results are presented using computation fluid dynamics with a validated v2f turbulence closure model. Turbulent flow characteristics and heat transfer performances in square channels with improved ribbed structures are numerically analyzed in this research work.
Findings
Based on the results, it is found that rounded transition cylindrical ribs have a large advantage over the conventional ribs in both enhancing heat transfer and reducing pressure loss penalty. In addition, cylindrical ribs increase the flow impingement at the upstream of the ribs, which will effectively increase the high heat transfer areas. The design of rounded transition cylindrical ribs and grooves will be an effective way to improve heat transfer enhancement and overall thermal performance of internal channels within blade cooling.
Originality/value
The novel geometries in this research are conventional cylindrical ribs with rounded transitions to the adjacent flat surfaces and with modifications at their bases. The combination of cylindrical ribs and grooves to manipulate the turbulent flow.
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Onur Ertuğrul, Zafer Çağatay Öter, Mustafa Safa Yılmaz, Ezgi Şahin, Mert Coşkun, Gürkan Tarakçı and Ebubekir Koç
The purpose of this paper is to evaluate the effect of post process combinations, e.g. hot isostatic pressing (HIP) only, HIP + T6 heat treatments, and T6 only, with different…
Abstract
Purpose
The purpose of this paper is to evaluate the effect of post process combinations, e.g. hot isostatic pressing (HIP) only, HIP + T6 heat treatments, and T6 only, with different aging time, on surface properties, microstructure and mechanical properties of stress-relieved AlSi10Mg parts produced by direct laser metal sintering.
Design/methodology/approach
HIP process and HIP + T6 heat treatments were applied to as stress-relieved direct laser metal sintered (DMLS) AlSi10Mg parts. Aging times of 4 and 12 h are selected to examine the optimum duration. To analyze the advantages of HIP process, a T6 heat treatment with 4 h of aging was also applied. Densities, open porosities and roughness values of as stress-relieved, HIPed, HIP + T6, and T6-only samples were measured. The samples were characterized by OM and SEM together with EDX analysis. An image analysis study was made to evaluate the inner pore structure, thereby to understand the mechanical behavior.
Findings
HIP process does not cause a significant change in surface porosity; yet it has a positive influence on inner porosity. HIP process results in a microstructure of the aluminum matrix surrounded by a network of micron and nano size Si particles. Additional heat treatment results in larger particles and precipitation. After HIPing, ductility increases but strength decreases. Samples aged 4 h present improved yield and tensile strength but decreased elongation, yet samples aged for 12 h reach a combination of optimum strength and ductility. The lower level of tensile strength and ductility in T6-only condition indicates that HIP process plays a crucial role in elimination of the porosity thus improves the effectiveness of subsequent heat treatment.
Originality/value
The study investigates the effect of post-process conditions and optimizes the aging time of the T6 heat treatment after HIP process in order to obtain improved mechanical properties. The stress-relieved state was chosen as the reference to prevent distortion during HIPing or heat treatment.
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Sachin Ambade, Chetan Tembhurkar, Awanikumar Patil and Diwesh Babruwan Meshram
This paper aims to study the effect of number of welding passes on microstructure, mechanical and corrosion properties of 409 M ferritic stainless steel. Shielded metal arc…
Abstract
Purpose
This paper aims to study the effect of number of welding passes on microstructure, mechanical and corrosion properties of 409 M ferritic stainless steel. Shielded metal arc welding (SMAW) process is used to weld two metal sheets of 409 M having 3 mm thickness as bead-on-plate with single, double and triple passes. Microstructures were observed at transverse section with the help of optical microscope and with increasing number of passes grain growth, and the width of heat-affected zone (HAZ) increases. The results of tensile tests revealed that as number of passes increases, there is reduction in tensile strength and ductility. Double loop electrochemical potentiokinetic reactivation (DL-EPR) test revealed that as number of passes increases, the degree of sensitization increases. This is due to the deposition of chromium carbides at the grain boundaries and the associated depletion of chromium.
Design/methodology/approach
Three welded plates of single, double and triple pass were welded by SMAW process. From three welded plates (single, double and triple passes), samples for microstructural examination were cut in transverse direction (perpendicular to welding direction) with the help of wire-cut electrical discharge machine (EDM). The welded plates were sliced using wire-cut EDM along transverse direction for preparing optical microscopy, tensile testing, microhardness and DL-EPR testing specimens.
Findings
From the microstructure, it was observed that the large grain growth, which is dendritic, and the structure become finer to increase in number of welding passes. As number of passes increases, the width of HAZ increases because of the higher temperature at the welded zone. The tensile strength decreases to increase the number of welding passes because of grain coarsening and chromium carbide precipitation in sensitized zone and wider HAZ. The maximum microhardness value was observed for single-pass weld as compared to double- and triple-pass welds because of the fast cooling rate. The degree of sensitization increases to increase the number of passes because of chromium carbide deposition at the grain boundaries.
Originality/value
The authors declare that the manuscript is original and not published elsewhere, and there is no conflict of interest to publish this manuscript.
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Lei Luo, Chenglong Wang, Lei Wang, Bengt Ake Sunden and Sangtao Wang
The dimple is adopted into a double wall cooling structure which is widely used in hot gas components to increase the heat transfer effects with relatively low pressure drop…
Abstract
Purpose
The dimple is adopted into a double wall cooling structure which is widely used in hot gas components to increase the heat transfer effects with relatively low pressure drop penalty. The purpose of this paper is to study the effect of dimple depth and dimple diameter on the target surface heat transfer and the inlet to outlet friction factor.
Design/methodology/approach
The study is carried out by using the numerical simulations. The impingement flow is directly impinging on the dimple and released from the film holes after passing the double wall chamber. The ratio between dimple depth and dimple diameter is varied from 0 to 0.4 and the ratio between dimple diameter and impingement hole diameter is ranging from 0.5 to 3. The Reynolds number is between 10,000 and 70,000. Results of the target surface Nusselt number, friction factor and flow structures are included. For convenience of comparison, the double wall cooling structure without the dimple is considered as the baseline.
Findings
It is found that the dimple can effectively enhance the target surface heat transfer due to thinning of the flow boundary layer and flow reattachment as well as flow recirculation outside the dimple near the dimple rim especially for the large Re number condition. However, the stagnation point heat transfer is reduced. It is also found that for a large dimple depth or large dimple diameter, a salient heat transfer reduction occurs for the toroidal vortex. The thermal performance indicates that the intensity of the heat transfer enhancement depends upon the dimple depth and dimple diameter
Originality/value
This is the first time to adopt a dimple into a double wall cooling structure. It suggests that the target surface heat transfer in a double wall cooling structure can be increased by the use of the dimple. However, the heat transfer characteristic is sensitive for the different dimple diameter and dimple depth which may result in a different flow behavior
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