Excellence in Research and Innovation for Humanity

International Science Index

Commenced in January 1999 Frequency: Monthly Edition: International Paper Count: 31

Mechanical, Aerospace, Industrial, Mechatronic and Manufacturing Engineering

  • 2017
  • 2016
  • 2015
  • 2014
  • 2013
  • 2012
  • 2011
  • 2010
  • 2009
  • 2008
  • 2007
  • 31
    Three Dimensional Modeling of Mixture Formation and Combustion in a Direct Injection Heavy-Duty Diesel Engine
    Due to the stringent legislation for emission of diesel engines and also increasing demand on fuel consumption, the importance of detailed 3D simulation of fuel injection, mixing and combustion have been increased in the recent years. In the present work, FIRE code has been used to study the detailed modeling of spray and mixture formation in a Caterpillar heavy-duty diesel engine. The paper provides an overview of the submodels implemented, which account for liquid spray atomization, droplet secondary break-up, droplet collision, impingement, turbulent dispersion and evaporation. The simulation was performed from intake valve closing (IVC) to exhaust valve opening (EVO). The predicted in-cylinder pressure is validated by comparing with existing experimental data. A good agreement between the predicted and experimental values ensures the accuracy of the numerical predictions collected with the present work. Predictions of engine emissions were also performed and a good quantitative agreement between measured and predicted NOx and soot emission data were obtained with the use of the present Zeldowich mechanism and Hiroyasu model. In addition, the results reported in this paper illustrate that the numerical simulation can be one of the most powerful and beneficial tools for the internal combustion engine design, optimization and performance analysis.
    Simulation of Roughness Shape and Distribution Effects on Rarefied and Compressible Flows at Slip Flow Regime
    A numerical simulation of micro Poiseuille flow has performed for rarefied and compressible flow at slip flow regimes. The wall roughness is simulated in two cases with triangular microelements and random micro peaks distributed on wall surfaces to study the effects of roughness shape and distribution on flow field. Two values of Mach and Knudsen numbers have used to investigate the effects of rarefaction as well as compressibility. The numerical results have also checked with available theoretical and experimental relations and good agreements has achieved. High influence of roughness shape can be seen for both compressible and incompressible rarefied flows. In addition it is found that rarefaction has more significant effect on flow field in microchannels with higher relative roughness. It is also found that compressibility has more significant effects on Poiseuille number when relative roughness increases.
    A Real Time Collision Avoidance Algorithm for Mobile Robot based on Elastic Force
    This present paper proposes the modified Elastic Strip method for mobile robot to avoid obstacles with a real time system in an uncertain environment. The method deals with the problem of robot in driving from an initial position to a target position based on elastic force and potential field force. To avoid the obstacles, the robot has to modify the trajectory based on signal received from the sensor system in the sampling times. It was evident that with the combination of Modification Elastic strip and Pseudomedian filter to process the nonlinear data from sensor uncertainties in the data received from the sensor system can be reduced. The simulations and experiments of these methods were carried out.
    Control of Pendulum on a Cart with State Dependent Riccati Equations
    State Dependent Riccati Equation (SDRE) approach is a modification of the well studied LQR method. It has the capability of being applied to control nonlinear systems. In this paper the technique has been applied to control the single inverted pendulum (SIP) which represents a rich class of nonlinear underactuated systems. SIP modeling is based on Euler-Lagrange equations. A procedure is developed for judicious selection of weighting parameters and constraint handling. The controller designed by SDRE technique here gives better results than existing controllers designed by energy based techniques.
    Knowledge Sharing based on Semantic Nets and Mereology to Avoid Risks in Manufacturing
    The right information at the right time influences the enterprise and technical success. Sharing knowledge among members of a big organization may be a complex activity. And as long as the knowledge is not shared, can not be exploited by the organization. There are some mechanisms which can originate knowledge sharing. It is intended, in this paper, to trigger these mechanisms by using semantic nets. Moreover, the intersection and overlapping of terms and sub-terms, as well as their relationships will be described through the mereology science for the whole knowledge sharing system. It is proposed a knowledge system to supply to operators with the right information about a specific process and possible risks, e.g. at the assembly process, at the right time in an automated manufacturing environment, such as at the automotive industry.
    Geometry Calibration Factors of Modified Arcan Fracture Test for Welded Joint
    In this study the mixed mode fracture mechanics parameters were investigated for high tensile steel butt welded joint based on modified Arcan test and finite element analysis was used to evaluate the effect of crack length on fracture criterion. The nondimensional stress intensity factors, strain energy release rates and Jintegral energy on crack tip were obtained for various in-plane loading combinations on Arcan specimen starting from pure mode-I to pure mode-II loading conditions. The specimen and apparatus were modeled by finite element method and analyzed under various loading angles (between 0 to 90 degrees with 15 degree interval) to simulate the pure mode-I, II and mixed mode fracture. Since the analytical results are independent from elasticity modules for isotropic materials, therefore the results in elastic fields can be used for Arcan specimens. The main objective of this study was to evaluate the geometric calibration factors for modified Arcan test specimen in order to obtain fracture toughness under mixed mode loading conditions.
    Stress Analysis of Adhesively Bonded Double- Lap Joints Subjected to Combined Loading
    Adhesively bonded joints are preferred over the conventional methods of joining such as riveting, welding, bolting and soldering. Some of the main advantages of adhesive joints compared to conventional joints are the ability to join dissimilar materials and damage-sensitive materials, better stress distribution, weight reduction, fabrication of complicated shapes, excellent thermal and insulation properties, vibration response and enhanced damping control, smoother aerodynamic surfaces and an improvement in corrosion and fatigue resistance. This paper presents the behavior of adhesively bonded joints subjected to combined thermal loadings, using the numerical methods. The joint configuration considers aluminum as central adherend with six different outer adherends including aluminum, steel, titanium, boronepoxy, unidirectional graphite-epoxy and cross-ply graphite-epoxy and epoxy-based adhesives. Free expansion of the joint in x direction was permitted and stresses in adhesive layer and interfaces calculated for different adherends.
    Design and Fabrication of a Column-Climber Robot (Koala Robot)
    This paper proposes a robot able to climb Columns. This robot is not dependent on the diameter and material of the columns. Some climbing robots have been designed up to now but Koala robot was designed and fabricated for climbing columns exclusively. Simple kinematics of climbing in the nature inspired us to design this robot. We used two linear mechanisms to grip the column. The gripper consists of a DC motor and a power screw mechanism with a linear bushing as a guide. This mechanism provides enough force to grip the column. In addition we needed an actuator for climbing the column; hence, two pneumatic jacks were used. All the mechanical parts were designed according to the exerted forces and operational condition. The prototype can be simply installed and controlled on the column by an inexperienced operator. This robot is intended for inspection and surveillance of pipes in oil industries and power poles in electric industries.
    Application of the Data Distribution Service for Flexible Manufacturing Automation
    This paper discusses the applicability of the Data Distribution Service (DDS) for the development of automated and modular manufacturing systems which require a flexible and robust communication infrastructure. DDS is an emergent standard for datacentric publish/subscribe middleware systems that provides an infrastructure for platform-independent many-to-many communication. It particularly addresses the needs of real-time systems that require deterministic data transfer, have low memory footprints and high robustness requirements. After an overview of the standard, several aspects of DDS are related to current challenges for the development of modern manufacturing systems with distributed architectures. Finally, an example application is presented based on a modular active fixturing system to illustrate the described aspects.
    Switched Reluctance Generator for Wind Power Applications
    Green house effect has becomes a serious concern in many countries due to the increase consumption of the fossil fuel. There have been many studies to find an alternative power source. Wind energy found to be one of the most useful solutions to help in overcoming the air pollution and global. There is no agreed solution to conversion of wind energy to electrical energy. In this paper, the advantages of using a Switched Reluctance Generator (SRG) for wind energy applications. The theoretical study of the self excitation of a SRG and the determination of the variable parameters in a SRG design are discussed. The design parameters for the maximum power output of the SRG are computed using Matlab simulation. The designs of the circuit to control the variable parameters in a SRG to provide the maximum power output are also discussed.
    Development a New Model of EEVC/WG17 Lower Legform for Pedestrian Safety
    Development, calibration and validation of a threedimensional model of the Legform impactor for pedestrian crash with bumper are presented. Lower limb injury is becoming an increasingly important concern in vehicle safety for both occupants and pedestrians. In order to prevent lower extremity injuries to a pedestrian when struck by a car, it is important to elucidate the loadings from car front structures on the lower extremities and the injury mechanism caused by these loadings. An impact test procedure with a legform addressing lower limb injuries in car pedestrian accidents has been proposed by EEVC/WG17. In this study a modified legform impactor is introduced and validated against EEVC/WG17 criteria. The finite element model of this legform is developed using LS-DYNA software. Total mass of legform impactor is 13.4 kg.Technical specifications including the mass and location of the center of gravity and moment of inertia about a horizontal axis through the respective centre of gravity in femur and tibia are determined. The obtained results of legform impactor static and dynamic tests are as specified in the EEVC/WG17.
    Fracture Toughness Characterization of Carbon-Epoxy Composite using Arcan Specimen
    In this study the behavior of interlaminar fracture of carbon-epoxy thermoplastic laminated composite is investigated numerically and experimentally. Tests are performed with Arcan specimens. Testing with Arcan specimen gives the opportunity of utilizing just one kind of specimen for extracting fracture properties for mode I, mode II and different mixed mode ratios of materials with exerting load via different loading angles. Variation of loading angles in range of 0-90° made possible to achieve different mixed mode ratios. Correction factors for various conditions are obtained from ABAQUS 2D finite element models which demonstrate the finite shape of Arcan specimens used in this study. Finally, applying the correction factors to critical loads obtained experimentally, critical interlaminar fracture toughness of this type of carbon- epoxy composite has been attained.
    Effect of Fuel Spray Angle on Soot Formation in Turbulent Spray Flames
    Results are presented from a combined experimental and modeling study undertaken to understand the effect of fuel spray angle on soot production in turbulent liquid spray flames. The experimental work was conducted in a cylindrical laboratory furnace at fuel spray cone angle of 30º, 45º and 60º. Soot concentrations inside the combustor are measured by filter paper technique. The soot concentration is modeled by using the soot particle number density and the mass density based acetylene concentrations. Soot oxidation occurred by both hydroxide radicals and oxygen molecules. The comparison of calculated results against experimental measurements shows good agreement. Both the numerical and experimental results show that the peak value of soot and its location in the furnace depend on fuel spray cone angle. An increase in spray angle enhances the evaporating rate and peak temperature near the nozzle. Although peak soot concentration increase with enhance of fuel spray angle but soot emission from the furnace decreases.
    Study on Ultrasonic Vibration Effects on Grinding Process of Alumina Ceramic (Al2O3)
    Nowadays, engineering ceramics have significant applications in different industries such as; automotive, aerospace, electrical, electronics and even martial industries due to their attractive physical and mechanical properties like very high hardness and strength at elevated temperatures, chemical stability, low friction and high wear resistance. However, these interesting properties plus low heat conductivity make their machining processes too hard, costly and time consuming. Many attempts have been made in order to make the grinding process of engineering ceramics easier and many scientists have tried to find proper techniques to economize ceramics' machining processes. This paper proposes a new diamond plunge grinding technique using ultrasonic vibration for grinding Alumina ceramic (Al2O3). For this purpose, a set of laboratory equipments have been designed and simulated using Finite Element Method (FEM) and constructed in order to be used in various measurements. The results obtained have been compared with the conventional plunge grinding process without ultrasonic vibration and indicated that the surface roughness and fracture strength improved and the grinding forces decreased.
    A New Analytical Approach for Free Vibration of Membrane from Wave Standpoint
    In this paper, an analytical approach for free vibration analysis of rectangular and circular membranes is presented. The method is based on wave approach. From wave standpoint vibration propagate, reflect and transmit in a structure. Firstly, the propagation and reflection matrices for rectangular and circular membranes are derived. Then, these matrices are combined to provide a concise and systematic approach to free vibration analysis of membranes. Subsequently, the eigenvalue problem for free vibration of membrane is formulated and the equation of membrane natural frequencies is constructed. Finally, the effectiveness of the approach is shown by comparison of the results with existing classical solution.
    Mixed-Mode Study of Rock Fracture Mechanics by using the Modified Arcan Specimen Test
    This paper studies mixed-mode fracture mechanics in rock based on experimental and numerical analyses. Experiments were performed on sharp-cracked specimens using the modified Arcan specimen test loading device. The modified Arcan specimen test was, in association with a special loading device, an appropriate apparatus for experimental mixed-mode fracture analysis. By varying the loading angle from 0° to 90°, pure mode-I, pure mode-II and a wide range of mixed-mode data were obtained experimentally. Using the finite element results, correction factors applied to the rectangular fracture specimen. By employing experimentally measured critical loads and the aid of the finite element method, mixed-mode fracture toughness for the limestone under consideration determined.
    Rotor Bearing System Analysis Using the Transfer Matrix Method with Thickness Assumption of Disk and Bearing
    There are lots of different ways to find the natural frequencies of a rotating system. One of the most effective methods which is used because of its precision and correctness is the application of the transfer matrix. By use of this method the entire continuous system is subdivided and the corresponding differential equation can be stated in matrix form. So to analyze shaft that is this paper issue the rotor is divided as several elements along the shaft which each one has its own mass and moment of inertia, which this work would create possibility of defining the named matrix. By Choosing more elements number, the size of matrix would become larger and as a result more accurate answers would be earned. In this paper the dynamics of a rotor-bearing system is analyzed, considering the gyroscopic effect. To increase the accuracy of modeling the thickness of the disk and bearings is also taken into account which would cause more complicated matrix to be solved. Entering these parameters to our modeling would change the results completely that these differences are shown in the results. As said upper, to define transfer matrix to reach the natural frequencies of probed system, introducing some elements would be one of the requirements. For the boundary condition of these elements, bearings at the end of the shaft are modeled as equivalent spring and dampers for the discretized system. Also, continuous model is used for the shaft in the system. By above considerations and using transfer matrix, exact results are taken from the calculations. Results Show that, by increasing thickness of the bearing the amplitude of vibration would decrease, but obviously the stiffness of the shaft and the natural frequencies of the system would accompany growth. Consequently it is easily understood that ignoring the influences of bearing and disk thicknesses would results not real answers.
    Product-Based Industrial Information Systems (Application to the Steel Industry)
    This paper shows a simple and effective approach to the design and implementation of Industrial Information Systems (IIS) oriented to control the characteristics of each individual product manufactured in a production line and also their manufacturing conditions. The particular products considered in this work are large steel strips that are coiled just after their manufacturing. However, the approach is directly applicable to coiled strips in other industries, like paper, textile, aluminum, etc. These IIS provide very detailed information of each manufactured product, which complement the general information managed by the ERP system of the production line. In spite of the high importance of this type of IIS to guarantee and improve the quality of the products manufactured in many industries, there are very few works about them in the technical literature. For this reason, this paper represents an important contribution to the development of this type of IIS, providing guidelines for their design, implementation and exploitation.
    Numerical Investigation of Delamination in Carbon-Epoxy Composite using Arcan Specimen
    In this paper delamination phenomenon in Carbon-Epoxy laminated composite material is investigated numerically. Arcan apparatus and specimen is modeled in ABAQUS finite element software for different loading conditions and crack geometries. The influence of variation of crack geometry on interlaminar fracture stress intensity factor and energy release rate for various mixed mode ratios and pure mode I and II was studied. Also, correction factors for this specimen for different crack length ratios were calculated. The finite element results indicate that for loading angles close to pure mode-II loading, a high ratio of mode-II to mode-I fracture is dominant and there is an opposite trend for loading angles close to pure mode-I loading. It confirms that by varying the loading angle of Arcan specimen pure mode-I, pure mode-II and a wide range of mixed-mode loading conditions can be created and tested. Also, numerical results confirm that the increase of the mode- II loading contribution leads to an increase of fracture resistance in the CF/PEI composite (i.e., a reduction in the total strain energy release rate) and the increase of the crack length leads to a reduction of interlaminar fracture resistance in the CF/PEI composite (i.e., an increase in the total interlaminar strain energy release rate).
    Fast Depth Estimation with Filters
    Fast depth estimation from binocular vision is often desired for autonomous vehicles, but, most algorithms could not easily be put into practice because of the much time cost. We present an image-processing technique that can fast estimate depth image from binocular vision images. By finding out the lines which present the best matched area in the disparity space image, the depth can be estimated. When detecting these lines, an edge-emphasizing filter is used. The final depth estimation will be presented after the smooth filter. Our method is a compromise between local methods and global optimization.
    Exploiting Machine Learning Techniques for the Enhancement of Acceptance Sampling
    This paper proposes an innovative methodology for Acceptance Sampling by Variables, which is a particular category of Statistical Quality Control dealing with the assurance of products quality. Our contribution lies in the exploitation of machine learning techniques to address the complexity and remedy the drawbacks of existing approaches. More specifically, the proposed methodology exploits Artificial Neural Networks (ANNs) to aid decision making about the acceptance or rejection of an inspected sample. For any type of inspection, ANNs are trained by data from corresponding tables of a standard-s sampling plan schemes. Once trained, ANNs can give closed-form solutions for any acceptance quality level and sample size, thus leading to an automation of the reading of the sampling plan tables, without any need of compromise with the values of the specific standard chosen each time. The proposed methodology provides enough flexibility to quality control engineers during the inspection of their samples, allowing the consideration of specific needs, while it also reduces the time and the cost required for these inspections. Its applicability and advantages are demonstrated through two numerical examples.
    Identification of the Electronic City Application Obstacles in Iran
    Amazing development of the information technology, communications and internet expansion as well as the requirements of the city managers to new ideas to run the city and higher participation of the citizens encourage us to complete the electronic city as soon as possible. The foundations of this electronic city are in information technology. People-s participation in metropolitan management is a crucial topic. Information technology does not impede this matter. It can ameliorate populace-s participation and better interactions between the citizens and the city managers. Citizens can proffer their ideas, beliefs and votes through digital mass media based upon the internet and computerization plexuses on the topical matters to receive appropriate replies and services. They can participate in urban projects by becoming cognizant of the city views. The most significant challenges are as follows: information and communicative management, altering citizens- views, as well as legal and office documents Electronic city obstacles have been identified in this research. The required data were forgathered through questionnaires to identify the barriers from a statistical community comprising specialists and practitioners of the ministry of information technology and communication, the municipality information technology organization. The conclusions demonstrate that the prioritized electronic city application barriers in Iran are as follows: The support quandaries (non-financial ones), behavioral, cultural and educational plights, the security, legal and license predicaments, the hardware, orismological and infrastructural curbs, the software and fiscal problems.
    Effects of Rarefaction and Compressibility on Fluid Flow at Slip Flow Regime by Direct Simulation of Roughness
    A two dimensional numerical simulation has been performed for incompressible and compressible fluid flow through microchannels in slip flow regime. The Navier-Stokes equations have been solved in conjunction with Maxwell slip conditions for modeling flow field associated with slip flow regime. The wall roughness is simulated with triangular microelements distributed on wall surfaces to study the effects of roughness on fluid flow. Various Mach and Knudsen numbers are used to investigate the effects of rarefaction as well as compressibility. It is found that rarefaction has more significant effect on flow field in microchannels with higher relative roughness. It is also found that compressibility has more significant effects on Poiseuille number when relative roughness increases. In addition, similar to incompressible models the increase in average fRe is more significant at low Knudsen number flows but the increase of Poiseuille number duo to relative roughness is sharper for compressible models. The numerical results have also validated with some available theoretical and experimental relations and good agreements have been seen.
    Application of Fuzzy Logic in Fault Diagnosis in Transformers using Dissolved Gas based on Different Standards
    One of the problems in fault diagnosis of transformer based on dissolved gas, is lack of matching the result of fault diagnosis of different standards with the real world. In this paper, the result of the different standards is analyzed using fuzzy and the result is compared with the empirical test. The comparison between the suggested method and existing methods indicate the capability of the suggested method in on-line fault diagnosis of the transformers. In addition, in some cases the existing standards are not able to diagnose the fault. In theses cases, the presented method has the potential of diagnosing the fault. The information of three transformers is used to the show the capability of the suggested method in diagnosing the fault. The results validate the capability of the presented method in fault diagnosis of the transformer.
    Effects of Nanolayer Structure and Brownian Motion of Particles in Thermal Conductivity Enhancement of Nanofluids
    Nanofluids are novel fluids that are going to have an important role in future industrial thermal device designs. Studies are being predominantly conducted on the mechanism of these heat transfers. The key to this attraction is in the increase in thermal conductivity brought about by the Nanofluids compared with the base fluid. Different models have been proposed for calculation of effective thermal conduction that has been gradually modified. In this investigation effect of nanolayer structure and Brownian motion of particles are studied and a new modified thermal conductivity model is proposed. Temperature, concentration, nanolayer thickness and particle size are taken as variables and their effect are studied simultaneously on the thermal conductivity of the fluids, showing the concentration of the nanoparticles to affect the nanolayer thickness which also affects the Brownian motion.
    Evaluation of Exerting Force on the Heating Surface Due to Bubble Ebullition in Subcooled Flow Boiling
    Vibration characteristics of subcooled flow boiling on thin and long structures such as a heating rod were recently investigated by the author. The results show that the intensity of the subcooled boiling-induced vibration (SBIV) was influenced strongly by the conditions of the subcooling temperature, linear power density and flow velocity. Implosive bubble formation and collapse are the main nature of subcooled boiling, and their behaviors are the only sources to originate from SBIV. Therefore, in order to explain the phenomenon of SBIV, it is essential to obtain reliable information about bubble behavior in subcooled boiling conditions. This was investigated at different conditions of coolant subcooling temperatures of 25 to 75°C, coolant flow velocities of 0.16 to 0.53m/s, and linear power densities of 100 to 600 W/cm. High speed photography at 13,500 frames per second was performed at these conditions. The results show that even at the highest subcooling condition, the absolute majority of bubbles collapse very close to the surface after detaching from the heating surface. Based on these observations, a simple model of surface tension and momentum change is introduced to offer a rough quantitative estimate of the force exerted on the heating surface during the bubble ebullition. The formation of a typical bubble in subcooled boiling is predicted to exert an excitation force in the order of 10-4 N.
    A Dynamic Model for a Drill in the Drilling Process
    The dynamic model of a drill in drilling process was proposed and investigated in this study. To assure a good drilling quality, the vibration variation on the drill tips during high speed drilling is needed to be investigated. A pre-twisted beam is used to simulate the drill. The moving Winkler-Type elastic foundation is used to characterize the tip boundary variation in drilling. Due to the variation of the drill depth, a time dependent dynamic model for the drill is proposed. Results simulated from this proposed model indicate that an abrupt natural frequencies drop are experienced as the drill tip tough the workpiece, and a severe vibration is induced. The effects of parameters, e.g. drilling speed, depth, drill size and thrust force on the drill tip responses studied.
    Continuous and Discontinuous Shock Absorber Control through Skyhook Strategy in Semi-Active Suspension System (4DOF Model)
    Active vibration isolation systems are less commonly used than passive systems due to their associated cost and power requirements. In principle, semi-active isolation systems can deliver the versatility, adaptability and higher performance of fully active systems for a fraction of the power consumption. Various semi-active control algorithms have been suggested in the past. This paper studies the 4DOF model of semi-active suspension performance controlled by on–off and continuous skyhook damping control strategy. The frequency and transient responses of model are evaluated in terms of body acceleration, roll angle and tire deflection and are compared with that of a passive damper. The results show that the semi-active system controlled by skyhook strategy always provides better isolation than a conventional passively damped system except at tire natural frequencies.
    A 7DOF Manipulator Control in an Unknown Environment based on an Exact Algorithm
    An exact algorithm for a n-link manipulator movement amidst arbitrary unknown static obstacles is presented. The algorithm guarantees the reaching of a target configuration of the manipulator in a finite number of steps. The algorithm is reduced to a finite number of calls of a subroutine for planning a trajectory in the presence of known forbidden states. The polynomial approximation algorithm which is used as the subroutine is presented. The results of the exact algorithm implementation for the control of a seven link (7 degrees of freedom, 7DOF) manipulator are given.
    Optimal Speed Controller Design of the Two-Inertia Stabilization System
    This paper focuses on systematic analysis and controller design of the two-inertia STABILIZATION system, considering the angular motion on a base body. This approach is essential to the stabilization system to aim at a target under three or six degrees of freedom base motion. Four controllers, such as conventional PDF(Pseudo-Derivative Feedback) controller with motor speed feedback, PDF controller with load speed feedback, modified PDF controller with motor-load speed feedback and feedforward controller added to modified PDF controller, are suggested to improve reference tracking and disturbance rejection performance. Characteristics and performance of each controller are analyzed and validated by simulation in the case of the modified PDF controller with and without a feedforward controller.
    A CFD Study of Sensitive Parameters Effect on the Combustion in a High Velocity Oxygen-Fuel Thermal Spray Gun
    High-velocity oxygen fuel (HVOF) thermal spraying uses a combustion process to heat the gas flow and coating material. A computational fluid dynamics (CFD) model has been developed to predict gas dynamic behavior in a HVOF thermal spray gun in which premixed oxygen and propane are burnt in a combustion chamber linked to a parallel-sided nozzle. The CFD analysis is applied to investigate axisymmetric, steady-state, turbulent, compressible, chemically reacting, subsonic and supersonic flow inside and outside the gun. The gas velocity, temperature, pressure and Mach number distributions are presented for various locations inside and outside the gun. The calculated results show that the most sensitive parameters affecting the process are fuel-to-oxygen gas ratio and total gas flow rate. Gas dynamic behavior along the centerline of the gun depends on both total gas flow rate and fuel-to-oxygen gas ratio. The numerical simulations show that the axial gas velocity and Mach number distribution depend on both flow rate and ratio; the highest velocity is achieved at the higher flow rate and most fuel-rich ratio. In addition, the results reported in this paper illustrate that the numerical simulation can be one of the most powerful and beneficial tools for the HVOF system design, optimization and performance analysis.