Thermoacoustic engine working principle

      

  From the acoustic point of view, it comprised a closed-ended ‘bounce volume’, a hot-end heat exchanger, a thermoacoustic stack, and a cold-end heat exchanger, terminating in a flange onto which the linear alternator would have been bolted, all enclosed in a duct of approximately constant cross-section. The bounce volume was necessary to allow useful magnitudes of acoustic velocity in the stack, but it also provided the radiant surface for transmission to the hot-end heatexchanger. The overall length of the duct was short compared with the acoustic wavelengths to be generated because their frequency was determined by the resonant frequency of the alternator.

Different Types of Metal Fabrication Processes

 

There are numerous types of metal fabrication processes used to transform raw metal materials into useful parts and components by using various metal working tools and fabrication machinery. Some of the more frequently used processes include:

Stamping: The metal is pressed in between a stamp die to create a raised section of the metal.

Punching: A punching tool is used to punch holes in the metal to create the desired part or component.

Cutting: Various cutting methods are used to cut the metal to the right size.

Folding: Sometimes the metal needs to be bent at a specific angle, and folding is used to achieve this result.

Machining: Machining processes carefully remove metal and reshape it into the end product and involve using drills, CNC lathes, and other such machinery.

Welding: This process involves heating two pieces of metal together.

Shearing: Shearing is creating one long single cut on metal sheets to cut it to the correct size.

Computational Fluid Dynamics

ANSYS ANALYSIS:

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Oil Fired Furnace ?

             Furnace oil is the major fuel used in oil fired furnaces, especially for reheating and heat treatment of materials. LDO is used in furnaces where presence of sulphur is undesirable. The key to efficient furnace operation lies in complete combustion of fuel with minimum excess air. Furnaces operate with efficiencies as low as 7% as against upto 90% achievable in other combustion equipment such as boiler. This is because of the high temperature at which the furnaces have to operate to meet the required demand. For example, a furnace heating the stock to 1200o C will have its exhaust gases leaving atleast at 1200o C resulting in a huge heat loss through the stack. However, improvements in efficiencies have been brought about by methods such as preheating of stock, preheating of combustion air and other waste heat recovery systems. 

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How the Furnace Energy Supply Works?

           

                    Since the products of flue gases directly contact the stock, type of fuel chosen is of importance. For example, some materials will not tolerate sulphur in the fuel. Also use of solid fuels will generate particulate matter, which will interfere the stock place inside the furnace. Hence, vast majority of the furnaces use liquid fuel, gaseous fuel or electricity as energy input. Melting furnaces for steel, cast iron use electricity in induction and arc furnaces. Non-ferrous melting utilizes oil as fuel. 

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Characteristics of an Efficient Furnace ?

              Furnace should be designed so that in a given time, as much of material as possible can be heated to an uniform temperature as possible with the least possible fuel and labour. To achieve this end, the following parameters can be considered.

• Determination of the quantity of heat to be imparted to the material or charge.

• Liberation of sufficient heat within the furnace to heat the stock and overcome all heat losses.

• Transfer of available part of that heat from the furnace gases to the surface of the heating stock. 

• Equalisation of the temperature within the stock.

• Reduction of heat losses from the furnace to the minimum possible extent. 

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Types and Classification of Different Furnaces?

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CHEMICAL PROCESSING FOR FURNACE?

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PHYSICAL PROCESSING FOR FURNACE ?

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What are the components of a furnace?

The principle components are

i. Source of energy
a) Fossil fuel: For fossil fuel one requires burner for efficient mixing of fuel and air. Arrangement of burner is important.
b) Electric energy: Resistance heating, induction heating or arc heating.
c) Chemical energy: Exothermic reactions

ii. Suitable refractory material: Refractory design is important. Thermal enclosure of the furnace is designed and constructed keeping in view the requirements. For example refractory facing the thermal enclosure must have high refractoriness, chemically inert etc. Whereas refractory facing the surrounding must have low thermal conductivity to minimize heat y installing a heat exchanger or internally by recirculation the POC within the ntation and control: Furnaces are equipped with POC analyzer and temperature control. urnaces and their applications in high temperature industries: escription in order to appreciate the requirement of the design of thermal enclosure, i.e. furnace): PHYSICAL PROCESSING losses

iii. Heat exchanger:

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What is a furnace?

              A furnace is essentially a thermal enclosure and is employed to process raw materials at high temperatures both in solid state and liquid state. Several industries like iron and steel making, non ferrous metals production, glass making, manufacturing, ceramic processing, calcination in cement production etc. employ furnace. The principle objectives are a) To utilize heat efficiently so that losses are minimum, and b) To handle the different phases (solid, liquid or gaseous) moving at different velocities for different times and temperatures such that erosion and corrosion of the refractory are minimum. 

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Countermeasure against molding defect ?

Defect
Warpage

Cause
1. Inappropriate gate location
2. Un even molded product thickness
3. Design of undercut, rib, and boss is inappropriate
4. Lack of cooling
5. Large anisotropic of shrinkage ratio

Countermeasure
1a. Change the gate location.
1b. Add the gates.
2. Try to make the molded product thickness even.
3. Change the design, thinking about warpage.
4. Drop the mold temperature, and make the cooling time longer.
5. Use the low warpage grade.

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Countermeasure against molding defects?

Defect
Strength poverty 

Cause
1. Lack of drying
2. High resin temperature
3. Too much cushion volume
4. Shear heat generation at the runner and the gate
5. Residence time too long

Countermeasure
1. Preliminary dry the pellet well enough
2. Drop the cylinder temperature
3. Reduce the cushion volume
4. Make the runner and the gate bigger, and shorten the gate land.
5a. Use the molding machine with appropriate injection volume(about 1.5 to 3 times more than the cavity volume)
5b. If resin remains inside the cylinder by some kind of trouble, resume molding after purging it.  

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Selection of injection machine?

* Select by injection volume

* Select by mold clamping pressure

* Nozzle structure

* Injection mechanism

* Backflow prevention ring

* Drying machine

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Selection of injection machine Nozzle structure ?

                Open nozzle is common when molding NOVADURAN. The nozzle of commercially-supplied injection machine can be open nozzle or shut-off nozzle (Figure 1-1) but in any type, it is necessary to have a temperature control. If drooling from the nozzle is concerned, use the shut-off nozzle. However, it might cause burn and sunspot object by resin retention at the slide part, so be careful.  

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Selection of injection machine by mold clamping pressure ?

               Both toggle type and direct pressure type is suitable when molding NOVADURAN. The relation of molded product projected area A(cm2 ) and required mold clamping pressure P(ton) should be in the range indicated below.

 P ＝ （0.5～0.7）×A  

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Selection of injection machine by injection volume?

               As a guide, generally the injection machine should be selected so that molded product volume will become 30% to 80% of the machine's injection volume. When molding, the relation of the machine's injection volume Q(g) and one shot weight (sprue and runner weight included) W(g) should be in the range indicated below. 

 Q ＝ （1.3～1.5）×W

                       If the injection volume is too small, plasticization will not make it, and might lose its original physicality as a molded product because the resin will be sent without enough plasticization. On the other hand, if the injection volume is too big, residence time inside the cylinder will be longer and cause degradation by more chance. 

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Types of Injection machine ?

（1） Horizontal injection machine ：
                      Both mold clamping device and injection device compounded horizontally

（2） Vertical injection machine ：
                      Both mold clamping device and injection device compounded vertically

（3） Two-color injection machine

（4） Rotary injection machine

（5） Low foam injection machine

（6） Multi material injection machine

（7） Sandwich injection machine

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Injection Molding

               The injection machine is a machine that melt plasticize the molding material inside the heating cylinder and inject this into the mold tool to create the molded product by solidifying inside it. The injection machine is constructed of a mold clamping device that opens and closes the mold tool, and device that plasticize and inject the molding material.

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Types of patterns used in sand casting?

(a) solid pattern

(b) split pattern

(c) match-plate pattern

(d) cope and drag pattern

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Sand Casting?

               Sand Casting is simply melting the metal and pouring it into a preformed cavity, called mold, allowing (the metal to solidify and then breaking up the mold to remove casting. In sand casting expandable molds are used. So for each casting operation you have to form a new mold. 

• Most widely used casting process

. 

• Parts ranging in size from small to very large 

• Production quantities from one to millions

• Sand mold is used.

• Patterns and Cores – Solid, Split, Match-plate and Cope-and-drag Patterns – Cores – achieve the internal surface of the part 

Advantages of casting?

Advantages

• Design flexibility

• Reduced costs

• Dimensional accuracy

• Versatility in production

Disadvantages

• Lot of molten metal is wasted in riser & gating

• Casting may require machining to remove rough surfaces

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Casting and types of Casting?

Casting Casting is the process of producing metal parts by pouring molten metal into the mould cavity of the required shape and allowing the metal to solidify. The solidified metal piece is called as “casting”.

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EXPLAIN POWDER PROCESSING?

Powder processing is a manufacturing technique that produces parts from the powder of certain materials. The powders are pressed into the desired shape, (called pressing), and heated sufficiently to cause the particles to bond together into a solid component, (called sintering). Powder processing is common for metal materials, however ceramics may also be subject to powder processing techniques. There are many advantages to powder processing. With powder processing you can obtain consistent dimensional control of the product, keeping relatively tight tolerances, It also can produce parts with good surface finish. Parts can therefore be made into their final shape, requiring no further manufacturing processes. With powder processing there is very little waste of material. Since powder processing can be automated, it minimizes the need for labor, requiring small amounts of skilled labor. Metals that are difficult to work with other processes can be shaped easily, (ie. tungsten). Also, certain alloy combinations and cermet that can not be formed any other way, can be produced with this technique. 

                Lastly, parts can be produced with a controlled level of porosity, due to the nature of the process. Powder processes also have a number of disadvantages. The first is high cost. Powders are expensive compared to solid material, they are also difficult to store. Sintering furnaces and special presses are more complicated to construct than conventional machinery. Tooling is also very expensive. Since powders do not easily flow laterally in a die when pressed, there are geometric limitations to the parts that can be manufactured. Powder parts may have inferior mechanical properties, (unless they undergo a forging process). Finally, variations in material density throughout the part may be a problem, especially with more intricate geometries. Powder processing manufacturing is ideal for producing large quantities of moderately complex, small to medium size parts that do not require strong mechanical properties in the part's material. This is not true of some alternative powder processes, such as hot isostatic pressing, that can manufacture parts with superior mechanical properties. A process such as hot isostatic pressing, however, would not be efficient in the manufacture of large quantities of parts.       

                                  

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EXPLAIN FORMING?

The category of manufacturing by metal forming includes a large group of processes that use force to induce a shape change in a metal, by mechanical working and plastic deformation. The most desirable quality of a manufacturing material as a candidate for a metal forming process is high ductility and malleability and a lower yield strength of the material. When working with metals, an increase in temperature will result in a higher ductility and a lower yield strength. 

In manufacturing industry, metals are often formed at elevated temperatures. In addition to shape change, the metal forming process will usually change the mechanical properties of the part's material. Metal forming can close up vacancies within the metal, break up and distribute impurities and establish new, stronger grain boundaries. For these reasons, the metal forming process is known to produce parts with superior mechanical properties. With relation to temperature there are 3 types of forming. Cold working, (room temperature), warm working and hot working. Also, with relation to the surface area-to-volume of a material there are 2 main categories, bulk deformation and sheet forming. 

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EXPLAIN CASTING?

 Metal casting is definitely one of the oldest manufacturing processes. Castings have been found dating back 6000 years. Fundamentally, casting involves filling a mold with molten material. This material, upon solidification, takes the shape of the mold. There are two basic types of metal casting processes, expendable mold and permanent mold. Castings can be made into the same shape as the final product, being the only process required. Or sometimes, casting is the first manufacturing process in the production of a multi-process manufactured part. Metal casting can be used to make parts with complicated geometry, both internal and external. 

With casting, intricate parts can be made in a single piece. Metal casting can produce very small parts like jewelry, or enormous parts weighing several hundred tons, like components for very large machinery. Although careful influence of casting parameters and technique can help control material properties; a general disadvantage to metal casting is that the final product tends to contain more flaws and has a lower strength and ductility compared to that of other manufacturing processes, such as metal forming. 

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WHAT IS MANUFACTURING PROCESS AND GIVEN ITS TYPES?

This is a summary of the basic and most commonly used manufacturing processes in industry today. Any of these processes can be employed to produce a manufactured part. Also, remember when deciding how to produce manufactured items, a part may require a combination of these processes to facilitate its completion. For example, a cast part may require some machining before it becomes the final product. Or, a part may be produced through a powder metallurgy process, then undergo some kind of metal forming operation. The following describes the methods and techniques involved in each of these manufacturing processes. Always keep in mind how material properties relate to manufacturing process. Most manufacturing processes described below are for metals. Manufacturing processes for polymers and ceramics will be discussed separately, each given its respective section. These processes are often similar in nature to those for metals, (ie. polymers are essentially both cast and formed in different techniques), however they are different enough to be classified independently

TYPES OF TECHNIQUE

•                Casting
•                Forming
•              Powder Processing

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WHAT ARE TYPES OF MATERIAL USED IN MANUFACTURING PROCESS?

Metals: Metals are hard, malleable, (meaning capable of being shaped), and somewhat flexible materials. Metals are also very strong. Their combination of strength and flexibility makes them useful in structural applications. When the surface of a metal is polished it has a lustrous appearance; although this surface luster is usually obscured by the presence of dirt, grease and salt. Metals are not transparent to visible light. Also, metals are extremely good conductors of electricity and heat.

Ceramics: Ceramics are very hard and strong, but lack flexibility making them brittle. Ceramics are extremely resistant to high temperatures and chemicals. Ceramics can typically withstand more brutal environments than metals or polymers. Ceramics are usually not good conductors of electricity or heat.

Polymers: Polymers are mostly soft and not as strong as metals or ceramics. Polymers can be extremely flexible. Low density and viscous behavior under elevated temperatures are typical polymer traits. Polymers can be insulative to electricity.

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EXPLAIN CRANK AND LEVER MECHANISM?

A crank is an arm attached at right angles to a rotating shaft by which reciprocating motion is imparted to or received from the shaft. It is used to convert circularmotion into reciprocating motion, or vice versa. The arm may be a bent portion of the shaft, or a separate arm or disk attached to it. Attached to the end of the crank by a pivot is a rod, usually called a connectingrod. The end of the rod attached to the crank moves in a circular motion, while the other end is usually constrained to move in a linear sliding motion.

The term often refers to a human-powered crank which is used to manually turn an axle, as in a bicycle crankset or a brace and bit drill. In this case a person's arm or leg serves as the connecting rod, applying reciprocating force to the crank. There is usually a bar perpendicular to the other end of the arm, often with a freely rotatable handle or pedal attached.

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TYPES OF SPROCKET?

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EXPLAIN RACK & PINION MECHANISM?

    Rack and Pinion- 

       A rack is a toothed bar or rod that can be thought of as a sector gear with an infinitely large radius of curvature. Torque can be converted to linear force by meshing a rack with a pinion: the pinion turns; the rack moves in a straight line. Such a mechanism is used in automobiles to convert the rotation of the steering wheel into the left-to-right motion of the tie rod(s). Racks also feature in the theory of gear geometry, where, for instance, the tooth shape of an interchangeable set of gears may be specified for the rack (infinite radius), and the tooth shapes for gears of particular actual radii then derived from that. The rack and pinion gear type is employed in a rack railway.

THIS MECHANISM IS USED TO CONVERT ROTATING MOTION INTO SLIDING MOTION AND VICE VERSA....

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