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1 – 10 of 561Wenchang Wu, Zhenguo Yan, Yaobing Min, Xingsi Han, Yankai Ma and Zhong Zhao
The purpose of the present study is to develop a new numerical framework that can predict the supersonic base flow more accurately, including the development of axisymmetrically…
Abstract
Purpose
The purpose of the present study is to develop a new numerical framework that can predict the supersonic base flow more accurately, including the development of axisymmetrically separated shear layer and recompression shock. To this end, two aspects are improved and combined, i.e. a newly self-adaptive turbulence eddy simulation (SATES) turbulence modeling method and a high-order discretization numerical scheme. Furthermore, the performance of the new numerical framework within a general-purpose PHengLEI software is assessed in detail.
Design/methodology/approach
Satisfactory prediction of the supersonic separated shear layer with unsteady wake flow is quite challenging. By using a unified turbulence model called SATES combining high-order accurate discretization numerical schemes, the present study first assesses the performance of newly developed SATES for supersonic axisymmetric separation flows. A high-order finite differencing-based compressible computational fluid dynamics (CFD) code called PHengLEI is developed and several different numerical schemes are used to investigate the effects on shock-turbulence interactions, which include the monotonic upstream-centered scheme for conservation laws (MUSCL), weighted compact nonlinear scheme (WCNS) and hybrid cell-edge and cell-node dissipative compact scheme (HDCS).
Findings
Compared with the available experimental data and the numerical predictions, the results of SATES by using high-order accurate WCNS or HDCS schemes agree better with the experiments than the results by using the MUSCL scheme. The WCNS and HDCS can also significantly improve the prediction of flow physics in terms of the instability of the annular shear layer and the evolution of the turbulent wake.
Research limitations/implications
The small deviations in the recirculation region can be found between the present numerical results and experimental data, which could be caused by the inaccurate incoming boundary layer condition and compressible effects. Therefore, a proper incoming boundary layer condition with turbulent fluctuations and compressibility effects need to be considered to further improve the accuracy of simulations.
Practical implications
The present study evaluates a high-order discretization-based SATES turbulence model for supersonic separation flows, which is quite valuable for improving the calculation accuracy of aeronautics applications, especially in supersonic conditions.
Originality/value
For the first time, the newly developed SATES turbulence modeling method combining the high-order accurate WCNS or HDCS numerical schemes is implemented on the PHengLEI software and successfully applied for the simulations of supersonic separation flows, and satisfactory results are obtained. The unsteady evolutions of the supersonic annular shear layer are analyzed, and the hairpin vortex structures are found in the simulation.
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Reynolds-averaged Navier–Stokes (RANS) models often perform poorly in shock/turbulence interaction regions, resulting in excessive wall heat load and incorrect representation of…
Abstract
Purpose
Reynolds-averaged Navier–Stokes (RANS) models often perform poorly in shock/turbulence interaction regions, resulting in excessive wall heat load and incorrect representation of the separation length in shockwave/turbulent boundary layer interactions. The authors suggest that this can be traced back to inadequate numerical treatment of the inviscid fluxes. The purpose of this study is an extension to the well-known Harten, Lax, van Leer, Einfeldt (HLLE) Riemann solver to overcome this issue.
Design/methodology/approach
It explicitly takes into account the broadening of waves due to the averaging procedure, which adds numerical dissipation and reduces excessive turbulence production across shocks. The scheme is derived based on the HLLE equations, and it is tested against three numerical experiments.
Findings
Sod’s shock tube case shows that the scheme succeeds in reducing turbulence amplification across shocks. A shock-free turbulent flat plate boundary layer indicates that smooth flow at moderate turbulence intensity is largely unaffected by the scheme. A shock/turbulent boundary layer interaction case with higher turbulence intensity shows that the added numerical dissipation can, however, impair the wall heat flux distribution.
Originality/value
The proposed scheme is motivated by implicit large eddy simulations that use numerical dissipation as subgrid-scale model. Introducing physical aspects of turbulence into the numerical treatment for RANS simulations is a novel approach.
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Rene Prieler, Simon Pletzer, Stefan Thusmer, Günther Schwabegger and Christoph Hochenauer
In fire resistance tests (FRTs) of building materials, a crucial criterion to pass the test procedure is to avoid the leakage of the hot flue gases caused by gaps and cracks…
Abstract
Purpose
In fire resistance tests (FRTs) of building materials, a crucial criterion to pass the test procedure is to avoid the leakage of the hot flue gases caused by gaps and cracks occurring due to the thermal exposure. The present study's aim is to calculate the deformation of a steel door, which is embedded within a wall made of bricks, and qualitatively determine the flue gas leakage.
Design/methodology/approach
A computational fluid dynamics/finite element method (CFD/FEM) coupling was introduced representing an intermediate approach between a one-way and a full two-way coupling methodology, leading to a simplified two-way coupling (STWC). In contrast to a full two way-coupling, the heat transfer through the steel door was simulated based on a one-way approach. Subsequently, the predicted temperatures at the door from the one-way simulation were used in the following CFD/FEM simulation, where the fluid flow inside and outside the furnace as well as the deformation of the door were calculated simultaneously.
Findings
The simulation showed large gaps and flue gas leakage above the door lock and at the upper edge of the door, which was in close accordance to the experiment. Furthermore, it was found that STWC predicted similar deformations compared to the one-way coupling.
Originality/value
Since two-way coupling approaches for fluid/structure interaction in fire research are computationally demanding, the number of studies is low. Only a few are dealing with the flue gas exit from rooms due to destruction of solid components. Thus, the present study is the first two-way approach dealing with flue gas leakage due to gap formation.
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Rilwan Kayode Apalowo, Mohamad Aizat Abas, Zuraihana Bachok, Mohamad Fikri Mohd Sharif, Fakhrozi Che Ani, Mohamad Riduwan Ramli and Muhamed Abdul Fatah bin Muhamed Mukhtar
This study aims to investigate the possible defects and their root causes in a soft-termination multilayered ceramic capacitor (MLCC) when subjected to a thermal reflow process.
Abstract
Purpose
This study aims to investigate the possible defects and their root causes in a soft-termination multilayered ceramic capacitor (MLCC) when subjected to a thermal reflow process.
Design/methodology/approach
Specimens of the capacitor assembly were subjected to JEDEC level 1 preconditioning (85 °C/85%RH/168 h) with 5× reflow at 270°C peak temperature. Then, they were inspected using a 2 µm scanning electron microscope to investigate the evidence of defects. The reliability test was also numerically simulated and analyzed using the extended finite element method implemented in ABAQUS.
Findings
Excellent agreements were observed between the SEM inspections and the simulation results. The findings showed evidence of discontinuities along the Cu and the Cu-epoxy layers and interfacial delamination crack at the Cu/Cu-epoxy interface. The possible root causes are thermal mismatch between the Cu and Cu-epoxy layers, moisture contamination and weak Cu/Cu-epoxy interface. The maximum crack length observed in the experimentally reflowed capacitor was measured as 75 µm, a 2.59% difference compared to the numerical prediction of 77.2 µm.
Practical implications
This work's contribution is expected to reduce the additional manufacturing cost and lead time in investigating reliability issues in MLCCs.
Originality/value
Despite the significant number of works on the reliability assessment of surface mount capacitors, work on crack growth in soft-termination MLCC is limited. Also, the combined experimental and numerical investigation of reflow-induced reliability issues in soft-termination MLCC is limited. These cited gaps are the novelties of this study.
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Abstract
Purpose
This paper aims to investigate the effect of frictional heat on the wear of high-speed rotary lip seals in engines.
Design/methodology/approach
In this research paper, the authors focus on the high-speed rotating lip seal of aircraft engines. Using the hybrid lubrication theory, a thermal-fluid-solid coupled numerical simulation model is established to investigate the influence of parameters such as contact pressure distribution, temperature rise and leakage rate on the sealing performance under different operating conditions. By incorporating the Rhee wear theory and combining simulation results with experimental data, a method for predicting the wear of the rotating seal lip profile is proposed. Experimental validation is conducted using a high-speed rotating test rig.
Findings
The results indicate that as the speed increases, the rise in frictional heat leads to a decrease in the sealing performance of the lip seal contact region. The experimental results show a similar trend to the numerical simulation results, and considering the effect of frictional heat, the predicted wear of the lip seal profile aligns more closely with the actual wear curve. This highlights the importance of considering the influence of frictional heat in the analysis of rotating seal mechanisms.
Originality/value
This study provides a reference for the prediction of wear profiles of engine high-speed rotary lip seals.
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Zuraihana Bachok, Aizat Abas, Hooi Feng Tang, Muhammad Zaim Hanif Nazarudin, Mohamad Fikri Mohd Sharif and Fakhrozi Che Ani
This study aims to investigate the influence of different solder alloy materials on passive devices during laser soldering process. Solder alloy material has been found to…
Abstract
Purpose
This study aims to investigate the influence of different solder alloy materials on passive devices during laser soldering process. Solder alloy material has been found to significantly influence the solder joint’s quality, such as void formation that can lead to cracks, filling time that affects productivity and fillet shape that determines the solder joint’s reliability.
Design/methodology/approach
Finite volume method (FVM)-based simulation that was validated using real laser soldering experiment is used to evaluate the effect of various solder alloy materials, including SAC305, SAC387, SAC396 and SAC405 in laser soldering. These solders are commonly used to assemble the pin-through hole (PTH) capacitor onto the printed circuit board.
Findings
The simulation results show how the void ratio, filling time and flow characteristics of different solder alloy materials affect the quality of the solder joint. The optimal solder alloy is SAC396 due to its low void ratio of 1.95%, fastest filling time (1.3 s) to fill a 98% PTH barrel and excellent flow characteristics. The results give the ideal setting for the parameters that can increase the effectiveness of the laser soldering process, which include reducing filling time from 2.2 s to less than 1.5 s while maintaining a high-quality solder joint with a void ratio of less than 2%. Industries that emphasize reliable soldering and effective joint formation gain the advantage of minimal occurrence of void formation, quick filling time and exceptional flowability offered by this solution.
Practical implications
This research is expected not only to improve solder joint reliability but also to drive advancements in laser soldering technology, supporting the development of efficient and reliable microelectronics assembly processes for future electronic devices. The optimized laser soldering material will enable the production of superior passive devices, meeting the growing demands of the electronics market for smaller, high-performance electronic products.
Originality/value
The comparison of different solder alloy materials for PTH capacitor assembly during the laser soldering process has not been reported to date. Additionally, volume of fluid numerical analysis of the quality and reliability of different solder alloy joints has never been conducted on real PTH capacitor assemblies.
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Sílvio Aparecido Verdério Júnior, Pedro J. Coelho and Vicente Luiz Scalon
The purpose of this study is to numerically investigate the geometric influence of different corrugation profiles (rectangular, trapezoidal and triangular) of varying heights on…
Abstract
Purpose
The purpose of this study is to numerically investigate the geometric influence of different corrugation profiles (rectangular, trapezoidal and triangular) of varying heights on the flow and the natural convection heat transfer process over isothermal plates.
Design/methodology/approach
This work is an extension and finalization of previous studies of the leading author. The numerical methodology was proposed and experimentally validated in previous studies. Using OpenFOAM® and other free and open-source numerical-computational tools, three-dimensional numerical models were built to simulate the flow and the natural convection heat transfer process over isothermal corrugation plates with variable and constant heights.
Findings
The influence of different geometric arrangements of corrugated plates on the flow and natural convection heat transfer over isothermal plates is investigated. The influence of the height ratio parameter, as well as the resulting concave and convex profiles, on the parameters average Nusselt number, corrected average Nusselt number and convective thermal efficiency gain, is analyzed. It is shown that the total convective heat transfer and the convective thermal efficiency gain increase with the increase of the height ratio. The numerical results confirm previous findings about the predominant effects on the predominant impact of increasing the heat transfer area on the thermal efficiency gain in corrugated surfaces, in contrast to the adverse effects caused on the flow. In corrugations with heights resulting in concave profiles, the geometry with triangular corrugations presented the highest total convection heat transfer, followed by trapezoidal and rectangular. For arrangements with the same area, it was demonstrated that corrugations of constant and variable height are approximately equivalent in terms of natural convection heat transfer.
Practical implications
The results allowed a better understanding of the flow characteristics and the natural convection heat transfer process over isothermal plates with corrugations of variable height. The advantages of the surfaces studied in terms of increasing convective thermal efficiency were demonstrated, with the potential to be used in cooling systems exclusively by natural convection (or with reduced dependence on forced convection cooling systems), including in technological applications of microelectronics, robotics, internet of things (IoT), artificial intelligence, information technology, industry 4.0, etc.
Originality/value
To the best of the authors’ knowledge, the results presented are new in the scientific literature. Unlike previous studies conducted by the leading author, this analysis specifically analyzed the natural convection phenomenon over plates with variable-height corrugations. The obtained results will contribute to projects to improve and optimize natural convection cooling systems.
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Rilwan Kayode Apalowo, Mohamad Aizat Abas, Fakhrozi Che Ani, Muhamed Abdul Fatah Muhamed Mukhtar and Mohamad Riduwan Ramli
This study aims to investigate the thermal fracture mechanism of moisture-preconditioned SAC305 ball grid array (BGA) solder joints subjected to multiple reflow and thermal…
Abstract
Purpose
This study aims to investigate the thermal fracture mechanism of moisture-preconditioned SAC305 ball grid array (BGA) solder joints subjected to multiple reflow and thermal cycling.
Design/methodology/approach
The BGA package samples are subjected to JEDEC Level 1 accelerated moisture treatment (85 °C/85%RH/168 h) with five times reflow at 270 °C. This is followed by multiple thermal cycling from 0 °C to 100 °C for 40 min per cycle, per IPC-7351B standards. For fracture investigation, the cross-sections of the samples are examined and analysed using the dye-and-pry technique and backscattered scanning electron microscopy. The packages' microstructures are characterized using an energy-dispersive X-ray spectroscopy approach. Also, the package assembly is investigated using the Darveaux numerical simulation method.
Findings
The study found that critical strain density is exhibited at the component pad/solder interface of the solder joint located at the most distant point from the axes of symmetry of the package assembly. The fracture mechanism is a crack fracture formed at the solder's exterior edges and grows across the joint's transverse section. It was established that Au content in the formed intermetallic compound greatly impacts fracture growth in the solder joint interface, with a composition above 5 Wt.% Au regarded as an unsafe level for reliability. The elongation of the crack is aided by the brittle nature of the Au-Sn interface through which the crack propagates. It is inferred that refining the solder matrix elemental compound can strengthen and improve the reliability of solder joints.
Practical implications
Inspection lead time and additional manufacturing expenses spent on investigating reliability issues in BGA solder joints can be reduced using the study's findings on understanding the solder joint fracture mechanism.
Originality/value
Limited studies exist on the thermal fracture mechanism of moisture-preconditioned BGA solder joints exposed to both multiple reflow and thermal cycling. This study applied both numerical and experimental techniques to examine the reliability issue.
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Weihua Zhang, Yuanchen Zeng, Dongli Song and Zhiwei Wang
The safety and reliability of high-speed trains rely on the structural integrity of their components and the dynamic performance of the entire vehicle system. This paper aims to…
Abstract
Purpose
The safety and reliability of high-speed trains rely on the structural integrity of their components and the dynamic performance of the entire vehicle system. This paper aims to define and substantiate the assessment of the structural integrity and dynamical integrity of high-speed trains in both theory and practice. The key principles and approaches will be proposed, and their applications to high-speed trains in China will be presented.
Design/methodology/approach
First, the structural integrity and dynamical integrity of high-speed trains are defined, and their relationship is introduced. Then, the principles for assessing the structural integrity of structural and dynamical components are presented and practical examples of gearboxes and dampers are provided. Finally, the principles and approaches for assessing the dynamical integrity of high-speed trains are presented and a novel operational assessment method is further presented.
Findings
Vehicle system dynamics is the core of the proposed framework that provides the loads and vibrations on train components and the dynamic performance of the entire vehicle system. For assessing the structural integrity of structural components, an open-loop analysis considering both normal and abnormal vehicle conditions is needed. For assessing the structural integrity of dynamical components, a closed-loop analysis involving the influence of wear and degradation on vehicle system dynamics is needed. The analysis of vehicle system dynamics should follow the principles of complete objects, conditions and indices. Numerical, experimental and operational approaches should be combined to achieve effective assessments.
Originality/value
The practical applications demonstrate that assessing the structural integrity and dynamical integrity of high-speed trains can support better control of critical defects, better lifespan management of train components and better maintenance decision-making for high-speed trains.
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Abstract
Purpose
This study aims to clarify the evolution law of stress field and fracture field during the mining process of inclined coal seam, to prevent the occurrence of roof burst water and impact ground pressure accident during the advancing process of working face.
Design/methodology/approach
The evolution law of stress-fracture field under different mining conditions of inclined coal seam was studied by using discrete element method and similar material simulation method.
Findings
The overburden stress at the lower end of the coal seam was mainly transmitted to the deep rock mass on the left side, and the overburden stress at the upper end was mainly transmitted to the floor direction. With the increase of the inclined length of the mining coal seam, the development of the fracture zone gradually evolves from the “irregular arch” form to the “transversely developed trapezoid” form. The development range of the fracture zone was always in the internal area of the stress concentration shell.
Originality/value
An original element of this paper is based on the condition that the dip angle of coal seam is 35°, and the evolution law of overburden stress-fracture field during the excavation of coal seam with different lengths was analyzed by UDEC numerical simulation software. The coupling relationship between stress shell and fracture field was proposed, and the development range of fracture zone was determined by stress. The value of this paper is to provide technical support and practical basis for the safety production of a mine working face.
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