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This study aims to minimize the pressure drop across wavy microchannels using secondary branches without compromising its capacity to transfer the heat. The impact of secondary flows on the pressure drop and heat transfer capabilities at different Reynolds numbers are investigated numerically for different wavy microchannels. Finally, different channels are evaluated using performance evaluation criteria to determine their effectiveness.

To investigate the flow and heat transfer capabilities in wavy microchannels having secondary branches, a 3D conjugate heat transfer model based on finite volume method is used. In conventional wavy microchannel, secondary branches are introduced at crest and trough locations. For the numerical simulation, a single symmetrical channel is used to minimize computational time and resources and the flow within the channels remains single-phase and laminar.

The findings indicate that the suggested secondary channels notably improve heat transfer and decrease pressure drop within the channels. At lower flow rates, the secondary channels demonstrate superior performance in terms of heat transfer. However, the performance declines as the flow rate increased. With the same amplitude and wavelength, the introduction of secondary channels reduces the pressure drop compared with conventional wavy channels. Due to the presence of secondary channels, the flow splits from the main channel, and part of the core flow gets diverted into the secondary channel as the flow takes the path of minimum resistance. Due to this flow split, the core velocity is reduced. An increase in flow area helps in reducing pressure drop.

Many complex and intricate microchannels are proposed by the researchers to augment heat dissipation. There are challenges in the fabrication of microchannels, such as surface finish and achieving the required dimensions. However, due to the recent developments in metal additive manufacturing and microfabrication techniques, the complex shapes proposed in this paper are feasible to fabricate.

Wavy channels are widely used in heat transfer and micro-fluidics applications. The proposed wavy microchannels with secondary channels are different when compared to conventional wavy channels and can be used practically to solve thermal challenges. They help achieve a lower pressure drop in wavy microchannels without compromising heat transfer performance.

The assembly simulation in tolerance analysis is one of the most important steps for the tolerance design of mechanical products. However, most assembly simulation methods are based on the rigid body assumption, and those assembly simulation methods considering deformation have a poor efficiency. This paper aims to propose a novel efficient and precise tolerance analysis method based on stable contact to improve the efficiency and reliability of assembly deformation simulation.

The proposed method comprehensively considers the initial rigid assembly state, the assembly deformation and the stability examination of assembly simulation to improve the reliability of tolerance analysis results. The assembly deformation of mating surfaces was first calculated based on the boundary element method with optimal initial assembly state, then the stability of assembly simulation results was assessed by the density-based spatial clustering of applications with noise algorithm to improve the reliability of tolerance analysis. Finally, combining the small displacement torsor theory, the tolerance scheme was statistically analyzed based on sufficient samples.

A case study of a guide rail model demonstrated the efficiency and effectiveness of the proposed method.

The present study only considered the form error when generating the skin model shape, and the waviness and the roughness of the matching surface were not considered.

To the best of the authors’ knowledge, the proposed method is original in the assembly simulation considering stable contact, which can effectively ensure the reliability of the assembly simulation while taking into account the computational efficiency.

The purpose of this paper is to improve the productivity and quality of the wire arc additive manufacturing process by benchmarking the strategies from the selected six strategies, namely, heat treatment process, inter pass cooling process, inter pass cold rolling process, peening process, friction stir processing and oscillation process.

To overcome the lack of certainty associated with correlations and relationships in quality functional deployment, fuzzy numbers have been integrated with the quality functional deployment framework. Twenty performance measures have been identified from the literature under five groups, namely, mechanical properties, physical properties, geometrical properties, cost and material properties. Using house of quality weights are allocated to performance measures and groups, relationships are established between performance measures and strategies, and correlations are assigned between strategies. Finally, for each strategy, relative importance, score and crisp values are calculated.

Inter pass cold rolling process strategy is computed with the highest crisp value of 15.80 which is followed by peening process, heat treatment process, friction stir processing, inter pass cooling process,] and oscillation process strategy.

To the best of the authors’ knowledge, there has been no research in the literature that analyzes the strategies to improve the quality and productivity of the wire arc additive manufacturing process.

This study aims to enhance merging of additive manufacturing (AM) techniques with powder injection molding (PIM). In this way, the prototypes could be 3D-printed and mass production implemented using PIM. Thus, the surface properties and mechanical performance of parts produced using powder/polymer binder feedstocks [material extrusion (MEX) and PIM] were investigated and compared with powder manufacturing based on direct metal laser sintering (DMLS).

PIM parts were manufactured from 17-4PH stainless steel PIM-quality powder and powder intended for powder bed fusion compounded with a recently developed environmentally benign binder. Rheological data obtained at the relevant temperatures were used to set up the process parameters of injection molding. The tensile and yield strengths as well as the strain at break were determined for PIM sintered parts and compared to those produced using MEX and DMLS. Surface properties were evaluated through a 3D scanner and analyzed with advanced statistical tools.

Advanced statistical analyses of the surface properties showed the proximity between the surfaces created via PIM and MEX. The tensile and yield strengths, as well as the strain at break, suggested that DMLS provides sintered samples with the highest strength and ductility; however, PIM parts made from environmentally benign feedstock may successfully compete with this manufacturing route.

This study addresses the issues connected to the merging of two environmentally efficient processing routes. The literature survey included has shown that there is so far no study comparing AM and PIM techniques systematically on the fixed part shape and dimensions using advanced statistical tools to derive the proximity of the investigated processing routes.

This paper aims to investigate the thermal performance of equivalent square and circular thermal systems and compare the heat transport and irreversibility of magnetohydrodynamic (MHD) nanofluid flow within these systems.

The research uses a constraint-based approach to analyze the impact of geometric shapes on heat transfer and irreversibility. Two equivalent systems, a square cavity and a circular cavity, are examined, considering identical heating/cooling lengths and fluid flow volume. The analysis includes parameters such as magnetic field strength, nanoparticle concentration and accompanying irreversibility.

This study reveals that circular geometry outperforms square geometry in terms of heat flow, fluid flow and heat transfer. The equivalent circular thermal system is more efficient, with heat transfer enhancements of approximately 17.7%. The corresponding irreversibility production rate is also higher, which is up to 17.6%. The total irreversibility production increases with Ra and decreases with a rise in Ha. However, the effect of magnetic field orientation (γ) on total EG is minor.

Further research can explore additional geometric shapes, orientations and boundary conditions to expand the understanding of thermal performance in different configurations. Experimental validation can also complement the numerical analysis presented in this study.

This research introduces a constraint-based approach for evaluating heat transport and irreversibility in MHD nanofluid flow within square and circular thermal systems. The comparison of equivalent geometries and the consideration of constraint-based analysis contribute to the originality and value of this work. The findings provide insights for designing optimal thermal systems and advancing MHD nanofluid flow control mechanisms, offering potential for improved efficiency in various applications.

This study aims to delve into the coupled mixed convective heat transport process within a grooved channel cavity using CuO-water nanofluid and an inclined magnetic field. The cavity undergoes isothermal heating from the bottom, with variations in the positions of heated walls across the grooved channel. The aim is to assess the impact of heater positions on thermal performance and identify the most effective configuration.

Numerical solutions to the evolved transport equations are obtained using a finite volume method-based indigenous solver. The dimensionless parameters of Reynolds number (1 ≤ Re ≤ 500), Richardson number (0.1 ≤ Ri ≤ 100), Hartmann number (0 ≤ Ha ≤ 70) and magnetic field inclination angle (0° ≤ γ ≤ 180°) are considered. The solved variables generate both local and global variables after discretization using the semi-implicit method for pressure linked equations algorithm on nonuniform grids.

The study reveals that optimal heat transfer occurs when the heater is positioned at the right corner of the grooved cavity. Heat transfer augmentation ranges from 0.5% to 168.53% for Re = 50 to 300 compared to the bottom-heated case. The magnetic field’s orientation significantly influences the average heat transfer, initially rising and then declining with increasing inclination angle. Overall, this analysis underscores the effectiveness of heater positions in achieving superior thermal performance in a grooved channel cavity.

This concept can be extended to explore enhanced thermal performance under various thermal boundary conditions, considering wall curvature effects, different geometry orientations and the presence of porous structures, either numerically or experimentally.

The findings are applicable across diverse fields, including biomedical systems, heat exchanging devices, electronic cooling systems, food processing, drying processes, crystallization, mixing processes and beyond.

This work provides a novel exploration of CuO-water nanofluid flow in mixed convection within a grooved channel cavity under the influence of an inclined magnetic field. The influence of different heater positions on thermomagnetic convection in such a cavity has not been extensively investigated before, contributing to the originality and value of this research.

This study aims to undertake a comprehensive examination of heat transfer by convection in porous systems with top and bottom walls insulated and differently heated vertical walls under a magnetic field. For a specific nanofluid, the study aims to bring out the effects of different segmental heating arrangements.

An existing in-house code based on the finite volume method has provided the numerical solution of the coupled nondimensional transport equations. Following a validation study, different explorations include the variations of Darcy–Rayleigh number (Ra_m = 10–10⁴), Darcy number (Da = 10^–5–10^–1) segmented arrangements of heaters of identical total length, porosity index (ε = 0.1–1) and aspect ratio of the cavity (AR = 0.25–2) under Hartmann number (Ha = 10–70) and volume fraction of φ = 0.1% for the nanoparticles. In the analysis, there are major roles of the streamlines, isotherms and heatlines on the vertical mid-plane of the cavity and the profiles of the flow velocity and temperature on the central line of the section.

The finding of a monotonic rise in the heat transfer rate with an increase in Ra_m from 10 to 10⁴ has prompted a further comparison of the rate at Ra_m equal to 10⁴ with the total length of the heaters kept constant in all the cases. With respect to uniform heating of one entire wall, the study reveals a significant advantage of 246% rate enhancement from two equal heater segments placed centrally on opposite walls. This rate has emerged higher by 82% and 249%, respectively, with both the segments placed at the top and one at the bottom and one at the top. An increase in the number of centrally arranged heaters on each wall from one to five has yielded 286% rate enhancement. Changes in the ratio of the cavity height-to-length from 1.0 to 0.2 and 2 cause the rate to decrease by 50% and increase by 21%, respectively.

Further research with additional parameters, geometries and configurations will consolidate the understanding. Experimental validation can complement the numerical simulations presented in this study.

This research contributes to the field by integrating segmented heating, magnetic fields and hybrid nanofluid in a porous flow domain, addressing existing research gaps. The findings provide valuable insights for enhancing thermal performance, and controlling heat transfer locally, and have implications for medical treatments, thermal management systems and related fields. The research opens up new possibilities for precise thermal management and offers directions for future investigations.