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For higher swirling flows (swirl > 0.5), flow confinement significantly impacts fluid flow, flame stability, flame length and heat transfer, especially when the confinement ratio is less than 9. Past numerical studies on helical axial swirler type systems are limited to non-reacting or reacting flows type Reynolds averaged Navier Stokes closure models, mostly are non-parametric studies. Effects of parametric studies like swirl angle and confinement on the unsteady flow field, either numerical or experimental, are very minimal. The purpose of this paper is to document modeling practices for a large eddy simulation (LES) type grid, predict the confinement effects of a single swirler lean direct injection (LDI) system and validate with literature data.

The first part of the paper discusses the approach followed for numerical modelling of LES with the minimum number of cells required across critical sections to capture the spectrum of turbulent energy with good accuracy. The numerical model includes all flow developing sections of the LDI swirler, right from the axial setting chamber to the exit of the flame tube, and its length is effectively modelled to match the experimental data. The computational model predicts unsteady features like vortex breakdown bubble, represented by a strong recirculation zone anchored downstream of the fuel nozzle. It is interesting to note that the LES is effective in predicting the secondary recirculation zones in the divergent section as well as at the corners of the tube wall.

The predictions of a single helical axial swirler with a vane tip angle of 60°, with a duct size of 2 × 2 square inches, are compared with the experimental data at several axial locations as well as with centerline data. Both mean and unsteady turbulent quantities obtained through the numerical simulations are validated with the experimental data (Cai et al., 2005). The methodology is extended to the confinements effect on mean flow characteristics. The time scale and length scale are useful parameters to get the desired results. The results show that with an increase in the confinement ratio, the recirculation length increases proportionally. A sample of three cases has been documented in this paper.

The novelty of the paper is the modelling practices (grid/unsteady models) for a parametric study of LDI are established, and the mean confinement effects are validated with experimental data. The spectrum of turbulent energies is well captured by LES, and trends are aligned with experimental data. The methodology can be extended to reacting flows also to study the effect of swirl angle, fuel injection on aerodynamics, droplet characteristics and emissions.

The purpose of this paper is to comprehensively evaluate the progress in the development of trapped vortex combustors (TVCs) in the past three decades. The review aims to identify the needs, predict the scope and discuss the challenges of numerical simulations in TVCs applied to gas turbines.

TVC is an emerging combustion technology for achieving low emissions in gas turbine combustors. The overall operation of such TVCs can be on very lean mixture ratio and hence it helps in achieving high combustion efficiency and low overall emission levels. This review introduces the TVC concept and the evolution of this technology in the past three decades. Various geometries that were explored in TVC research are listed and their operating principles are explained. The review then categorically arranges the progress in computational studies applied to TVCs.

Analyzing extensive literature on TVCs the review discusses results of numerical simulations of various TVC geometries. Numerical simulations that were used to optimize TVC geometry and to enhance mixing are discussed. Reactive flow studies to comprehend flame stability and emission characteristics are then listed for different TVC geometries.

To the best of the authors’ knowledge, this review is the first of its kind to discuss extensively the computational progress in TVC development specific to gas turbine engines. Earlier review on TVC covers a wide variety of applications including land-based gas turbines, supersonic Ramjets, incinerators and hence compromise on the depth of analysis given to gas turbine engine applications. This review also comprehensively group the numerical studies based on geometry, flow and operating conditions.

The purpose of this paper is to review the applications of the chemical reactor network (CRN) approach for modeling the combustion in gas turbine combustors and classify the CRN construction methods that have been frequently used by researchers.

This paper initiates with introducing the CRN approach as a practical tool for precisely predicting the species concentrations in the combustion process with lower computational costs. The structure of the CRN and its elements as the ideal reactors are reviewed in recent studies. Flow field modeling has been identified as the most important input for constructing the CRNs; thus, the flow field modeling methods have been extensively reviewed in previous studies. Network approach, component modeling approach and computational fluid dynamics (CFD), as the main flow field modeling methods, are investigated with a focus on the CRN applications. Then, the CRN construction approaches are reviewed and categorized based on extracting the flow field required data. Finally, the most used kinetics and CRN solvers are reviewed and reported in this paper.

It is concluded that the CRN approach can be a useful tool in the entire process of combustion chamber design. One-dimensional and quasi-dimensional methods of flow field modeling are used in the construction of the simple CRNs without detailed geometry data. This approach requires fewer requirements and is used in the initial combustor designing process. In recent years, using the CFD approach in the construction of CRNs has been increased. The flow field results of the CFD codes processed to create the homogeneous regions based on construction criteria. Over the past years, several practical algorithms have been proposed to automatically extract reactor networks from CFD results. These algorithms have been developed to identify homogeneous regions with a high resolution based on the splitting criteria.

This paper reviews the various flow modeling methods used in the construction of the CRNs, along with an overview of the studies carried out in this field. Also, the usual approaches for creating a CRN and the most significant achievements in this field are addressed in detail.

This paper aims to get an in-depth understanding of the fuel spray characteristics to further improve the emission performance of a lean premixed prevaporized (LPP) combustor with staged lean combustion.

In this paper, the fuel spray characteristics in the LPP combustor are experimentally studied by using particle image velocimetry (PIV), and raw data are processed by image-processing technologies for different inlet conditions. The effects of the fuel allocation and pilot atomizer position on fuel spray characteristics are investigated.

Experiment results show that when only the pilot atomizer is operated, the fuel spray characteristics is worsened by increasing fuel flow rate. The fuel spray fields generated by the pilot atomizer are better at the throat than that at the pilot swirler outlet; when the pilot atomizer and primary injector are operated at the same time with the same inlet fuel air ratio, the spray characteristics are improved by increasing the primary fuel flow rate and decreasing the pilot fuel flow rate. Meanwhile, fuel spray fields generated by the pilot atomizer are better at the throat than that at the pilot swirler outlet.

The present results are useful for further development of the LPP combustor.

An LPP combustor with staged lean combustion technology was proposed; to obtain fuel spray characteristics, image-processing program was compiled; the fuel spray characteristics in the LPP combustor were investigated, especially the effects of the fuel allocation and pilot atomizer position.

A combustor design is a particularly important and difficult task in the development of gas turbine engines. During studies for accurate and easy combustor design, reasonable design methodologies have been established and used in engine development. The purpose of this paper is to review the design methodology for combustor in development of advanced gas turbine engines. The advanced combustor development task can be successfully achieved in less time and at lower cost by adopting new and superior design methodologies.

The review considers the main technical problems (combustion, cooling, fuel injection and ignition technology) in the development of modern combustor design and deals with combustor design methods by dividing it into preliminary design, performance evaluation, optimization and experiment. The advanced combustion and cooling technologies mainly used in combustor design are mentioned in detail. In accordance with the modern combustor design method, the design mechanisms are considered and the methods used in every stage of the design are reviewed technically.

The improved performances and strict emission limits of gas turbine engines require the application of advanced technologies when designing combustors. The optimized design mechanism and reasonable performance evaluation methods are very important in reducing experiments and increasing the effectiveness of the design.

This paper provides a comprehensive review of the design methodology for the advanced gas turbine engine combustor.

The purpose of this paper is to investigate power performance, economy and hydrocarbons (HC)/carbon monoxide (CO) emissions of diesel fuel on a two-stoke direct injection (DI) spark ignition (SI) engine.

Experimental study was carried out on a two-stroke SI diesel-fuelled engine with air-assisted direct injection, whose power performance and HC/CO emissions characteristics under low-load conditions were analysed according to the effects of ignition energy, ignition advance angle (IAA), injection timing angle and excess-air-ratio.

The results indicate that, for the throttle position of 10%, a large IAA with adequate ignition energy effectively increases the power and decrease the HC emission. The optimal injection timing angle for power and fuel consumption is 60° crank angle (CA) before top dead centre (BTDC). Lean mixture improves the power performance with the HC/CO emissions greatly reduced. At the throttle position of 20%, the optimal IAA is 30°CA BTDC. The adequate ignition energy slightly improves the power output and greatly decreases HC/CO emissions. Advancing the injection timing improves the power and fuel consumption but should not exceed the exhaust port closing timing in case of scavenging losses. Burning stoichiometric mixture achieves maximum power, whereas burning lean mixture obviously reduces the fuel consumption and the HC/CO emissions.

Gasoline has a low flash point, a high-saturated vapour pressure and relatively high volatility, and it is a potential hazard near a naked flame at room temperature, which can create significant security risks for its storage, transport and use. The authors adopt a low volatility diesel fuel for all vehicles and equipment to minimise the number of different devices using various fuels and improve the potential military application safety.

Under low-load conditions, the two stroke port-injected SI engine performance of burning heavy fuels including diesel or kerosene was shown to be worse than those of gasoline. The authors have tried to use the DI method to improve the performance of the diesel-fuelled engine in starting and low-load conditions.

The purpose of this paper is to illustrate the successful application of Six Sigma at a small and medium scale plastic parts manufacturing unit. Overall operational excellence is one of the foundations of global competiveness. Indian industries are also keeping up with achieving and maintaining operational excellence through different improvement tools and methodologies. Plastic parts manufacturing industries in India are also on the move to increase their overall quality, productivity and profitability. However, it appears from the available literature that application of Six Sigma, one of the most effective breakthrough improvement strategies having direct impact on bottom line of the organization, is not being explored to its full potential, especially at plastic parts manufacturing industries in India. This study was thus undertaken at plastic products manufacturing plant to introduce Six Sigma to them by applying the same to their chronic problems and drawing improvements in quality, productivity and profitability.

This paper illustrates the real-life case study of improving quality and productivity of injection molding process by phase wiz application of define, measure, analyze, improve and control, the process improvement methodology of Six Sigma.

The critical defects, such as short molding, contamination, injection point and flash are reduced from the process leading to annual savings of INR 10.80 lacs. This is a considerable amount for a small concern in question.

Because this was the pilot project and the firm was of small and medium size, data collection was the major issue, which consequently took considerable time and efforts at define and measure phases. Injection molding is a very salient process for plastic products manufacturing. Almost one-third of plastic products are made by this process. Thus, improving quality of products made out of injection molding process is of paramount importance. The paper is an attempt to exhibit how a small-scale plastic injection molded parts manufacturing unit can put fruitful efforts to achieve competitive advantage through Six Sigma.

From the review of literature, it appears that application of Six Sigma among plastic parts manufacturing units, especially small and medium, is very rare, not in India but across the globe. This case study has opened up the direction to small- and medium-scale plastic parts manufacturing units to implement Six Sigma and to move a step forward toward achieving competitive advantage.

The purpose of this paper is to introduce a new methodology called overall greenness performance for value stream mapping (OGP-VSM). Using value-added concepts, this approach has the potential to integrate, measure, control and improve productive and environmental performance in accordance with a company’s context.

The OGP-VSM approach was developed by reviewing and integrating the environmental aspects of existing lean thinking tools and approaches.

This research revealed the lack of practical integration between productive and environmental performance. Using OGP-VSM, managers can see that environmental practices have a direct impact on productivity. OGP-VSM allows a balance to be found between lean and green practices in order to achieve the simultaneous improvement of productivity and environmental performance.

The proposed approach is applied to a case study in an automotive company in Spain and lays the groundwork for moving toward functional environmental sustainability in manufacturers.

Companies are increasingly implementing environmentally focused practices. Pursuing environmentally friendly (green) performance poses several challenges, but it also affords opportunities to create new methodologies for generating a competitive advantage for manufacturing companies. There are a limited number of approaches to drawing together the elements and attributes that are essential for a holistic, practical and long-lasting improvement of environmental performance in the manufacturing sector.

The purpose of this paper is to provide a demonstration of the application of techniques for robust optimization for improvement of the injection moulding processes in an injection moulding small and medium sized enterprise (SME).

A critical to quality characteristic (CtQ) which is connected to assembly problems is the subject of investigation. The CtQ is not directly measurable. The variation in a dimension of a product, which is correlated to the CtQ, is studied using design of experiments (DoE) and Taguchi methods. A two-cavity mould is used in the injection moulding process. To evaluate the robustness of the process using signal-to-noise analysis, the data were transformed to compensate for the systematic differences between the mould cavities.

The initial results showed that finding optimal process parameter settings commonly valid for both cavities was impossible. After a modification of the mould, the experiments were rerun and optimal settings could be found.

Applying DoE techniques in small and medium-sized injection moulding companies is far from common practice. This case study demonstrates a method to apply DoE with five process parameters which can serve as a standard method to prepare production when a new mould is used for the first time.

The originality is connected to the combination of the applied methods and, in the context of the case study, carried out in an SME unfamiliar with the power of the applied methods. The value of the paper is to demonstrate the power of the most powerful technique in quality engineering to improve an injection moulding process within the context of SMEs. The authors would accentuate the point that the true power becomes visible when this powerful technique is introduced into an organization with very little understanding of the technique. In addition, the case study is valuable to practitioners because it proposes a new scientific and systematic approach to understand and optimize the start-up of the moulding process.