A Statistical Approach in the Analysis of Geometrical Product Specification during the Cold Tube Drawing Process

Cold tube drawing provides higher accuracy compared to hot approaches. The process can be used to reduce the dimensions of tubes, and depending on the reduction size, the wall thickness of these may be subject to changes. In the process, any form of variability provoked by external factors is highly sensitive, given that the resulting tubes are often the final step in tube production. This paper focused on the evaluation of the influence of pre-tube factors on key variables after the drawing process, i.e., the final roundness, outer diameter, and wall thickness of the tubes. For these purposes, a factorial design with fixed factors was implemented. It was also a goal to investigate if the single-pass type of drawing would guarantee good statistical results potentially leading to significant time and financial reductions. The measurements were executed in the machine ZEISS CenterMax. The statistical analysis took place on Minitab 19. The results prove that most factors, and their interactions, significantly impacted the response variables, leading the authors to understand that a single-pass approach would not properly work under the conditions defined for the experimentation. These results also allow for reflection on the causes and necessary measures related to lubrication, technological heritage, and quality that would impact the results themselves.

Self-Assembled Corn-Husk-Shaped Fullerene Crystals as Excellent Acid Vapor Sensors

Low-molecular-weight acid vapors cause aging and destruction in material processing. In this paper, facile fabrication of novel corn-husk-shaped fullerene C60 crystals (CHFCs) through the dynamic liquid–liquid interfacial precipitation method is reported. The CHFCs were grown at the liquid–liquid interface between isopropyl alcohol (IPA) and a saturated solution of C60 in mesitylene under ambient temperature and pressure conditions. The average length, outer diameter, and inner diameter of CHFCs were ca. 2.88 μm, 672 nm, and 473 nm, respectively. X-ray diffraction (XRD) analysis showed the CHFCs exhibit a mixed face-centered cubic (fcc) and hexagonal-close pack (hcp) crystal phases with lattice parameters a = 1.425 nm, V = 2.899 nm3 for fcc phase and a = 2.182 nm, c = 0.936 nm, a/c ratio = 2.33, and V = 3.859 nm3 for hcp phase. The CHFCs possess mesoporous structure as confirmed by transmission electron microscopy (TEM) and nitrogen sorption analysis. The specific surface area and the pore volume were ca. 57.3 m2 g−1 and 0.149 cm3 g−1, respectively, are higher than the nonporous pristine fullerene C60. Quartz crystal microbalance (QCM) sensing results show the excellent sensing performance CHFCs sensitive to acetic acid vapors due to the enhanced diffusion via mesoporous architecture and hollow structure of the CHFCs, demonstrating the potential of the material for the development of a new sensor system for aliphatic acid vapors sensing.

Precise Inspection of Geometric Parameters for Polyvinyl Chloride Pipe Section Based on Computer Vision

The precise inspection of geometric parameters is crucial for quality control in the context of Industry 4.0. The current technique of precise inspection depends on the operation of professional personnel, and the measuring accuracy is restricted by the proficiency of operators. To solve the defects, this paper proposes a precise inspection framework for the geometric parameters of polyvinyl chloride (PVC) pipe section (G-PVC), using low-cost visual sensors and high-precision computer vision algorithms. Firstly, a robust imaging system was built to acquire images of a PVC pipe section under irregular illumination changes. Next, an engineering semantic model was established to calculate G-PVC like inner diameter, outer diameter, wall thickness, and roundness. After that, a region-of-interest (ROI) extraction algorithm was combined with an improved edge operator to obtain the coordinates of measured points on PVC end-face image in a stable and precise manner. Finally, our framework was proved highly precise and robust through experiments.

Improvement of test methods and criteria for evaluation of resistance to flame propagation of long elements of the wiring system

The test methods for flame propagation of long elements of the electrical wiring system, in particular, cables, cable conduits and ducts, are analyzed, and differences in them are found in the test conditions and criteria for evaluating the resistance to flame propagation. Using a substrate of a wooden board covered with a layer of tissue paper with an areal density of (21±9) g/m2, adopted for testing other elements of the electrical wiring system, a cable was identified that is not resistant to flame propagation. It is proposed to use this substrate for testing the flame propagation of cables instead of a substrate made of a double layer of filter paper with a surface density of (80±15) g/m2. In one of three experiments, a cable that was not resistant to flame propagation was found based on the criterion of the presence of ignition of the substrate located under it. To reduce the risk of making an incorrect decision on compliance, it is proposed that the assessment of long elements of the wiring system be carried out according to the rules established for cable ducts, trays and ladders in EN 50085-1 and IEC 61537. For the AVVG cable with an outer diameter of 10 mm to 60 mm, when it touches the blue flame cone of 1 kW, the correlation coefficient of the dependence of the length of the charred part on the diameter was 0.969. For a distance of 100 mm between the sample and the burner along its axis, a correlation coefficient of 0.985 was obtained. It is proposed to test cables under the second condition recommended in IEC 60695-11-2. For two conduits, flame propagation was revealed when exposed to a 1 kW flame for 120 s and 240 s. However, for these pipelines, flame propagation did not occur under standard conditions of exposure to such a flame for 20 s and 25 s. To identify long elements of the wiring system that are not resistant to flame propagation, it is proposed to test them at a duration of exposure to a flame of 1 kW, established for cables in IEC 60332-1-2

Study on the Selection of the Number of Magnetic Poles and the Slot-Pole Combinations in Fractional Slot PMSM Motor with a High Power Density

Fractional slot, PMSM motors with a properly designed electromagnetic circuit allow for obtaining high power density factors (more than 4 kW per 1 kg of total motor weight). The selection of the number of magnetic poles to the specific dimensions and operating conditions of the motor, as well as the number of slots for the selected number of magnetic poles is the subject of the analysis in this article. This issue is extremely important because it affects the mass of the motor, the value of shaft torque, shaft power and the value of rotor losses. The aim of the work is to select solutions with the highest values of power density factor and, at the same time, the lowest values of rotor losses. The object of the study is a fractional slot PMSM motor with an external solid rotor core with surface permanent magnets (SPM). Motor weight is approximately 10 kg, outer diameter is 200 mm and a maximum power is 50 kW at 4800 r/min. The article analyzes the selection of magnetic poles in the range from 2p = 12 to 2p = 24 and various slot-pole combinations for individual magnetic poles. The target function of the objective was achieved and the calculations results were verified on the physical model. The best solutions were 20-pole, 30-slots (highest efficiency and lowest rotor loss) and 24-pole, 27 slots (highest power density).

Influences of key parameters on flow features in the curved ducts with equal area

Curved ducts are widely used in aircraft engines to improve some capability of aero-engines. Complex internal flow characteristics would be induced by the curvature in such components. In this study, the influence of parameters, including the arc angle α, the curvature radius R i, and the height H, on the local accelerating and transonic flow in the curved ducts with equal area were studied numerically and theoretically under different nozzle pressure ratios (NPRs). The range of the Re number based on the height of the duct and the velocity at the inlet was [Formula: see text] ∼ [Formula: see text]. The shear stress transport κ-ω turbulent model was proved by the test data to suitably simulate the flow field in curved ducts because it could accurately predict the flow separations under adverse pressure gradients. The uncertainty of the pressure scan value to obtain the test data was ±0.05%. Numerical results showed that the effect of α on the flow characteristics of the curved ducts is little. The maximum Ma number in the curved section reduces with the increase of R i, and that grows with the increase of H. The range of the maximum Ma number was 1.20∼1.80. The critical NPRs, which decided the special flow features, were found in the curved ducts. The critical NPR rises with the increase of R i; however, the effect of H on the critical NPR is irregular due to the flow separations located near the lower wall induced by the large adverse pressure gradient. The theoretical results based on the small perturbation theory of transonic flow in the polar coordinate system proved that the distribution of sonic line was just dependent on the inner diameter R1, the outer diameter R2, and the arc angle θmax of the curved section. The critical mass flow and the critical NPR2 are only related to R1 and R2.

Non-Symmetrical Direct Extrusion—Analytical Modelling, Numerical Simulation and Experiment

The article presents the original technology of the extrusion of hollow curved pipes. The curvature radius of pipe axis was obtained directly during extrusion by eccentric alignment of the annular calibration gap of the extrusion die. Theoretical relationships describing the radius of curvature of the extruded part as a function of the eccentricity e of position of the annular calibration gap in the die were developed. A die with replaceable inserts with eccentricity e equal to 1, 2, 3, 5, 7 mm was designed and fabricated. Experimental tests were carried out to extrude lead pipes with an outer diameter of 20 mm and an inner diameter of 18 mm. Measurements of the radii of the curvature of the extruded pipes were consistent with the values calculated from the developed theoretical relationships. Numerical modelling of the proposed method of extrusion in a finite element-based QForm 3D program was carried out. The finite element method (FEM) numerical calculations were carried out for lead. Numerical simulations and experimental studies have shown that, by changing the value of the eccentric gap, the radius of curvature of the extruded pipe can be controlled.

Housingless ESPs for Slim Completion Wells

This paper describes a new electrical submersible pump (ESP) design concept to overcome the challenges of applications in slim well completions or thru-tubing deployment. The housing of the conventional pump is removed, allowing the pump impellers to have a larger diameter. The impact of this design change on pump hydraulic performance is assessed in this paper. Downhole ESPs operate in environments where space is limited radially. This is especially the case for slim completions or for thru-tubing rigless deployment. To provide the required rate and total dynamic head, the current approach is to use permanent magnetic motors and operate the slim systems at rotational speed over the conventional speed of 3500-4000 RPM. High-speed operations require new pump stage designs to minimize erosion and vibration. This paper provides an alternative pump design, which removes the pump housing with the benefit of increasing the impeller tip diameter, and hence potentially reducing pump length and operational speed. To ensure the pump retains the well fluids, the diffusers are designed to be externally threaded with an O-ring feature. The centrifugal pump affinity laws are applied to evaluate the impact of removing the pump housing and increasing the impeller outside diameter. A typical ESP housing wall thickness is about 0.18-0.25 inch. With the housing removed, the incremental space available for the impeller tip to occupy is increased by 0.36-0.5 inch. Analysis shows that, for the same pump speed as a conventional pump with a housing, a housingless pump will increase the head generated by 23-32%, and the rate capacity about 36-51%, depending on the pump series. In general, the smaller the pump outer diameter, the greater the flow and head capacity increase. This is because the available space due to removing the housing becomes a considerable size of the impeller tip diameter for the smaller series pumps. The elimination of pump housing enables impellers with a larger diameter to be used to generate more head per stage. In comparison to a conventional pump of the same outside diameter, and providing the same amount of total dynamic head, the housingless pump can have fewer stages and a shorter length or operate at a reduced speed. The reduced length can help mitigating pump-bending stress for installation in deviated or horizontal wells. The reduction in required operating speeds will reduce pump wears, heat generation and vibration. The housingless ESPs have applications for slim well completions or thru-tubing deployments.

Effect of Hydrogen, Hydride Orientation and Temperature on Low-Cycle Fatigue Resistance of Zr-1%Nb Fuel Rod Claddings

Low-cycle fatigue testing was conducted on annular samples with an outer diameter of 9.13 mm, a wall thickness of 0.68 mm and a width of 2.7 mm, namely: non-hydrogenated samples (cut out of standard Zr‑1%Nb cladding tubes); hydrogenated samples with a hydrogen concentration of 50 ... 400 ppm; samples cut out from hydrogenated dummy claddings after hydride reorientation tests performed according to various test modes. The tests were conducted at the temperatures of 25, 180, 350, 400 and 450 °С. The results obtained demonstrate that with increasing the hydrogen content in Zr-1%Nb alloy claddings the fatigue life increases.

OPTIMIZATION OF BELLOWS AND TUBES CUTTING BY DISC KNIFE TO ACHIEVE THE MINIMUM BURR SIZE

The paper solves the determination of the optimal size of the shear gap when dividing components with a circular cross section (hydroformed metal bellows and tubes) with a disc knife to achieve the smallest burr size on the divided surfaces. The analyzes were performed on bellows with an outer diameter of 15 mm and a wall thickness of 0.4 mm. During the experiments, the size of the shear gap between the inner disc knife and the outer knife was changed, and the pressing force of the inner disc knife was changed. The experiments were carried out using a cutting tool after 20,000 cuts and after 120,000 cuts. The optimal size of the cutting gap was determined, allowing the minimum size of the burr to be achieved, thus reducing the time to remove it by brushing or tumbling in the subsequent operation. The mentioned procedure can be applied to analogous cases of division.