Masters Degrees (Mechanical Engineering)

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The measurement of axial turbine tip clearance flow phenomena in a moving wall annular cascade and in a linear cascade.
(1989) Morphis, George.; Bindon, Jeffrey Peter.
On unshrouded axial flow turbine rotors, the tip clearance, required for thermal expansion and manufacturing limitations, allows fluid to leak from the pressure side to the suction side of the blade. This flow across the blade tip causes a large proportion of the overall rotor loss. In this work, the flow was visualized, microscopic static pressures taken and flow field measurements were done in the blade tip region to investigate the complex nature of tip clearance flows. An annular turbine cascade with a rotating outer casing was used to simulate the relative motion at the tip of an axial rotor. It was found that relative motion did not have a significant effect on the basic structure of the micro-flow, even though it reduced the leakage mass flow rate which is important as far as mixing loss formation is concerned. The existence of a narrow, very low pressure depression, caused by the flow remaining attached around the sharp pressure corner edge, was confirmed. The width and pressure of the separation bubble were found to be strongly dependent on gap size but the relationship was not linear. The point at which the separation bubble reattaches was seen to coincide with a slight rise in static pressure. The separation bubble which caused the majority of the internal gap loss, and which was thought to contribute to the mixing loss, was shown to disappear when the pressure corner was given a radius of 2,5 gap widths.A linear cascade was used to evaluate the performance of two blade tip shapes that substantially reduced internal gap loss and to compare them to a standard sharp or flat tip blade. A method whereby linear cascade data was analyzed as if it were a rotor with work transfer, was used to evaluate the performance of the various blade tip geometries. It was found that both modified tips increased the mixing loss due to the extra leakage mass flow rate. The first tip with the radiused pressure corner was seen to have a lower efficiency than the flat tip blade. A second tip that was contoured to shed flow in a radial direction and thus decrease the leakage mass flow rate through the gap was seen to significantly increase the overall efficiency.
The use of discrete event simulation techniques to optimize a proposed factory layout.
(1989) Gokal, Manooj.; Guthrie, A. M.
This project has proved conclusively that discrete event simulation techniques can be used to simulate, on computer, a complex stochastic materials handling system. The packing, automatic palletising and warehousing departments of a large powders manufacturing factory was used as an example to investigate the capabilities of computer simulation. The company intends to increase the number of packing machines from seven to eleven, and has embarked on productivity improvement projects that aims to increase the average packing efficiency from the current 50%, to 60% with a long term goal of 70%. Due to the stochastic nature of the run and stop durations of the packing machines, it was impossible to predict the effect of the increased throughput on the palletising system by conventional means. The system was modelled on computer using the SIMAN simulation language. Extensive research was initially carried out in order to determine the operating parameters of the system. The generation of cases from the packing machines in the program was verified against actual production runs. Various alternatives were analyzed to assist in decision making on the expansion of the palletising system in order to accommodate the increased throughput expected from the packing floor. The simulation was therefore used to increase the capacity of the automatic palletising system at minimal cost while meeting demands from the packing floor. It was established that the only capital expenditure required would be about R500 000 to increase the capacity of a palletiser and to provide a pallet conveyor to transport 40% of the pallets to direct despatch.
High temperature fatigue crack growth behaviour of TIMETAL 21S in an oxidizing environment.
(1995) Ferreira, Jacques Henri.; Aghion, E. E.
The high temperature fatigue crack growth behaviour of the newly developed, metastable titanium-based alloy, TIMETAL 21S, was investigated in an inert and an oxidizing environment. The investigation adopted a two pronged approached, namely, to initially establish the pure microstructural behaviour under oxidizing and inert environments at various elevated temperatures, and consequently, to establish the environmental effects on the fatigue crack growth behaviour in the various environments at high temperature. The effect of the oxidizing environment on the metastable alloy and on the mechanical and chemical events occurring at the fatigue crack were studied by using optical and scanning electron microscopy, including ED X analysis, x-ray diffraction, and Auger Electron Spectroscopy (AES) . For the microstructural investigation, the TIMETAL 21S samples were exposed for 5 hours to a pure argon and argon + 20% O2 environment at 300°C to 750°C in increments of 50°C. The results showed that in the oxidizing environment a more homogeneous nucleation of the alpha phase had occurred at higher temperatures and that the oxide Ti02, in addition to the alpha case, had predominantly formed on the exposed surfaces. AES analysis showed that dissolution of the oxygen into the alloy occurred even at low temperatures. An LEFM approach was used to investigate fatigue crack growth rate (FCGR) of C(T) specimens at 375°C, 450°C, 550°C and 620°C in the argon and argon + 20% oxygen environment. The crack growth rates were monitored using load-line compliance and the beachmarking method - a method by which beach marks were impressed on the fracture surface to track the progressing crack. The results showed that the crack growth rates were lower in the oxidizing environment and was influenced by a synergistic effect of the temperature, stress intensity at the crack tip and the environment. In addition to the phenomena of crack tip shielding (a process whereby the effective crack tip driving force experienced at the crack tip was locally reduced), other mechanisms such as slip character modification and secondary cracking ahead of the crack tip, leading to crack tip blunting and branching, had to be incorporated to fully explain the crack growth behaviour. The tests conducted in the inert environment effectively excluded the effect of oxygen on the crack growth behaviour and substantiated that various mechanisms ultimately determined the FCGR in TIMETAL 21S at elevated temperatures.
The influence of sulphidizing attack on the mechanism of failure of coated superalloy under cyclic loading conditions.
(1998) Govender, Gonasagren.; Aghion, E. E.
A systematic study of the effect of sulphidizing atmosphere on the High Temperature Low Cycle Fatigue (HTLCF) properties of coated and uncoated unidirectionally solidified MARM002 nickel base superalloy was performed at 870°C. The coating systems investigated were, aluminide coating, three types of platinum modified aluminide coatings, and platinum coating. The creep-plasticity mode of the strain range partitioning method was used for creep-fatigue loading. A constant loading regime (Strain range 6.6 x 10-3 ) was used to test the samples in argon, air and Ar + 5%S02 and a lower strain range of3.8 x 10-3 was used to investigate the creep-fatigue properties in Ar + 5%S02 only. The results were analysed using scanning electron microscopy including spot analyses (SEM-EDS), Auger electron spectroscopy (AES) and X-ray diffraction (XRD) techniques. The synergistic effect of sulphidizing environment and the creep fatigue loading (Strain range - 0.66%) resulted in accelerated failure in all the materials systems tested, except for the TYPE I platinum aluminide coated sample. This coating displayed a "self-healing" mechanism which enhanced its fatigue life under sulphidizing conditions. In general, the coatings had an adverse effect on the fatigue properties of the material systems. This was due to the poor mechanical properties of the coating. The mechanical properties of the coating was influenced by the coating microstructure and the chemical composition. The modification of the NiAI zone with platinum in the platinum aluminide coatings improved the fatigue properties of the coating by altering the crack propagation mechanism in the NiAl zone. The higher the platinum content in this region the more brittle it became. The platinum modified aluminide coating showed an improvement in the corrosion fatigue properties in the S02 containing environment at the higher strain range when compared with the uncoated, aluminide coated and platinum coated samples. However, at the lower strain range all the coating systems performed worse than the uncoated alloy. This was mainly due to the brittle failure of the coating. The platinum modified aluminides performed the worst due to the presence of brittle platinum aluminide phases. The interdiffusion and interaction of platinum with the substrate alloying elements, resulted in this coating being ineffective for corrosion protection. The resultant coating layer produced poor corrosion-fatigue properties. Although the coating systems did show evidence of resistance to sulphidation and oxidation there were relatively ineffective under the combination of sulphidizing environment and fatigue loading due to their poor mechanical properties. The mechanism of sulphidation was consistent for all the material systems tested with oxidation proceeding first and sulphidation proceeding at the corrosion scale/substrate interface. The crack propagation in the coating and substrate was controlled by the sulphidation attack at the crack tip and failure of the oxide scales formed in the cracks.
Cordless linear synchronous motor material handling system for computer integrated manufacturing.
(2000) Lindsay, Craig Vaughn.; Bright, Glen.; Hippner, Maciej.
Advanced material handling systems' impact on flexible manufacturing systems (FMS) have increased the efficiency and work rate over conventional manufacturing assemblies. The interaction of automated guided vehicles (AGVs), roller conveyors and conveyor belts with robots and machine tools forms highly sophisticated assembly operations. Whilst material handling in FMS today is conventionally used to transport assembly units from one work station to another, it does not take an active role in the manufacturing process. With manufacturers implementing more advanced manufacturing principles to perform agile manufacturing, there is a growing need to implement "smarter" material handling systems that would perform essential, integral roles in the assembly process. This research outlines the development of a cordless linear synchronous motor (CLSM) material handling system. The CLSM incorporates a permanent magnet courier that moves without tether restrictions on an integrated reverse air bearing system which eliminates friction. The CLSM provides a material handling system with enhanced travel, flexibility and accuracy. The CLSM material handling system is designed to integrate with overhead manipulators and part feeders to form a comprehensive flexible manufacturing system. This research covers the 2-D finite element modeling (FEM) used to determine the CLSM's optimal parameters. The development of the motor windings design and construction, together with the control system for the CLSM, is also covered. The CLSM novel air bearing system is outlined and compared to other conventional linear bearing systems. The possible impact of the CLSM on current manufacturing systems is explored to determine the validity of the research project and possible further research opportunities.
The influence of process factors on the production of semi solid feedstock.
(2000) Cooper, Fredrik.; Govender, Gonasagren.
Semi-solid manufacturing is a near net shape forming process that takes advantage of an alloy's thixotropic behaviour. However, in order to obtain the desired thixotropic properties from an alloy in the semi -solid state, the microstructure of the as-cast feedstock metal needs to display a fine grained, equiaxed primary phase prior to reheating for the forming operation. Various methods are currently in use to obtain the required microstructure of which the MagnetoHydroDynamic (MHD) process is predominant. Two fundamental factors, namely shear rate and cooling rate, influence the formation of the fine grained, equiaxed primary phase during the MHD process. The aim of this research was to produce semi solid billets and in so doing, determine how the influence of the combination of the two fundamental factors contribute towards the final formation of the primary phase and to determine an optimal level ofthese factors' settings to deliver the desired microstructure. An MHD apparatus was constructed and the Taguchi method was used to design an experiment to investigate the influence ofthe fundamental factors involved in casting semi solid feedstock of aluminium A356.2. The issues ofthe formation of a fine eutectic phase and solidification shrinkage were also investigated. An experimental method was designed to investigate the significance ofthe fundamental factors' influence towards the appearance of the primary phase; the latter was evaluated using an image analysis system. The shear rate was controlled by varying the line frequency and the base frequency supplied to the electromagnetic stirrer and the cooling rate was controlled by initiation of a fixed, fast cooling rate at a certain melt temperature (TJ Results showed that a fine grained, equiaxed primary phase, with an average grain size of 55 /lm, was achieved after casting, prior to reheating for forming. The contribution of the base frequency and the line frequency were 8 % and 3.5 % respectively and the contribution ofTi was 86.5 % towards the outcome ofthe result. The cooling rate changed from approximately 0.3 QC/sec to 4.5 QC/sec at Ti. A fine textured eutectic phase was achieved with the fast cooling rate. The solidification shrinkage was accounted for by incorporating a riser on the mould. The feedstock produced in this research was compared, on a microstructural basis, to commercially available Semi Solid Metal (SSM) feedstock from Pechiney and SAG. The research feedstock had a larger, average primary grain size, however, it was more discrete and round grained than the commercial alloys which were finer and more rosette grained. Upon reheating to the semi solid state, ready for forming, the final, evolved grain sizes and shapes were almost identical between the research and commercial feedstock, despite the initial differences in grain sizes and shapes. However, the commercial alloys showed primary grains with trapped eutectic whereas in the research alloy, the primary grains were largely free of trapped eutectic.
The optimisation of train make-up and train handling-simulating longitudinal train dynamics.
(2000) Majola, Lumko.; Verijenko, Viktor.; Adali, Sarp.
The South African rail industry is undergoing a phase of restructuring and much focus is concentrated on re-engineering i.e. optimising the utilisation of available assets and using existing technology in order to improve efficiency; attention shifts to improved heavy haul asset management through train performance models. The computer programs presented in this thesis have been developed to calculate longitudinal in-train forces accruing in long heavy haul trains and their effect on train operations. The model of the train is implemented by dedicated differential equations for the movements of each vehicle. The simulation is menu driven for all input and output decisions using Microsoft Excel while the engine for the dynamic analysis is ACSL (Advanced Continuous Simulation Language). The main program is capable of simulating the operation of any train configuration over any route, including remote operation. The thesis comprises: - • a discussion on the need for alternative train configurations based on the current fleet and the potential of such operating changes; • the comparison of the dynamic response of trains operating with only head-end locomotives, trains operating with both head-end locomotives and remote locomotives and trains operating with different class locomotives in one locomotive consist; • the investigation of the lateral effects in the different train consists as a function of the longitudinal in-train force in the simulation environment; • the advantages of operating with remote locomotives in terms of increased train length, reduced force spectrum on vehicle components and improved energy consumption; • the implications of the optimum position of the in-train locomotive consist on loading and unloading operations; • the implications of different train configurations on driver technique or train handling and the need for an optimum driving strategy to gain maximum benefit from the locomotives.
A design methodology investigation and the design of a material handling system.
(2000) Govender, Daryl Sebastian.; Adali, Sarp.; Verijenko, Viktor.
This dissertation is undertaken under the auspices of both the CSIR, Division of Mining Technology and the University of Natal, School of Mechanical Engineering. The CSIR have outlined two fundamental objectives of the dissertation. Firstly, the need for competent design engineers has become increasingly evident. To this end, an evaluation and research into the science of design methodology has been conducted and regarded as a significant component of the thesis. The rationale behind this aim is that the subject of design has been practiced for thousands of years, but an understanding of the process is comparably in its infancy. The importance of the steps involved in the mechanical design process can in no uncertain terms be overemphasized as the adherence there to results in designs that are least likely prone to failure as well as the attainment of highly efficient product design time scales. This is vitally important more especially when the drive towards multifunctional multidisciplinary teams is rapidly developing in the global market place. Secondly, the CSIR, having done the appropriate market research, have defined the need for the design of a timber handling system to be implemented in a deep level mining environment. It is the authors expressed intent not to separate the theory from the design at hand but rather to allow this thesis to become, for the reader, forum where a holistic and integrated approach to design can be presented.
An investigation of the strength of an aircraft wing bolt with a centrally drilled hole.
(2000) Francis, Daniel.; Verijenko, Viktor.
The investigation contained herein is a part of a larger, long-term project: The Development of SMART Aircraft Bolts. Structural failures, at highly stressed components, arc common in some of the aircraft used by the South African Air force. The strength of one such component, the wing bolts on the C-130 aircraft, is analysed and compared to the stress distribution in a bolt which has a small hole drilled through the centre of the bolt (which will be used to insert a sensing device). The results of this analysis will be used as input into further phases of the project, e.g., SMART material selection and the development of sensing devices. Due to the complex physics of a bolted joint, advanced analysis of the bolt under conservative loading was performed, after conducting thorough research into bolted joint design and analysis methods, in order to provoke the final recommendations.
Optimisation and design of two micro-hydro turbines for medium and low head applications.
(2000) Randelhoff, Julian.; Smith, Graham Douglas James.
The necessity to develop an automated process for the design of micro-hydro power systems was based on the increasing demand for hydropower as a renewable energy source and to develop cost effective power supplies to rural areas. The application of the formula for the design of these systems is then to simplify the selection of the turbine sizing and is made possible by the similarity laws that exist within turbine and pump families. in addition the sizing of the supply and exhaust piping is also a matter of scaling. No selection process of turbine type is included due to the limitations of cost effectiveness and the category of size into which the turbine was specified. Furthermore. a new approach to turbine design was separately undertaken to satisfy low head and low flow-rate conditions. However, it was only designed up to a cost analysis with no manufacturing having been undertaken. The axial flow turbine. which was most suited for micro-hydro was designed and built as a prototype with a standardized mounting frame. The initial conditions used to generare the velocity vectors and angles were specific to the installation site and used to computationally generate the rotor and stator blades. This required an analysis of the different profiles available as well as research into their design. Once the blade profile stacking had been determined, this was translated into a software program that developed the blades from site-specific initial conditions. However, the design of the blades was interdependent on the dimensioning of the rest of the turbine components and designing these in parallel proved to be an intricate task. With the design complete, the turbine was then installed and testing proceeded with the use of pressure gauges and the results of torque and rpm obtained from a dynamometer. Analysis of the results was undertaken and presented in graphical format with comments on both the design and results.
Buckling of short, thin-walled cylinders, as applied to storage tanks.
(2001) Du Poujol, Geraldine Touche.; Bodger, Robert.; Adali, Sarp.
This is an investigation of the buckling characteristics of short, thin-walled cylinders. This study was required as large storage tanks, which were converted from Boating roof to fixed roofed tanks, were found to buckle when severe atmospheric temperature drops and thus pressure differentials occurred. These severe ambient temperature changes are characteristic of the Highveld in South Africa where the tanks in question are situated. Since this modification is an uncommon procedure, codes of practice for storage vessels do not cover this type of cylinder. For the same reason, research performed in this field is limited. Buckling due to axial loading, lateral external pressure, hydrostatic pressure and a combination of axial loading and hydrostatic pressure are explored in this study. To compare with and verify theory, existing research for each case is examined, and the Finite Element Analysis package MSC Nastran used to determine trends. In some cases, to the best of the author's knowledge, no research exists and numerical analysis is performed to establish the relationships present in those cases. The study is extended to include the design of imperfect cylinders, as defined in the tank code AD Merkblatter where it is stated as being dependant on the major and minor diameters of the imperfect section . The study is also extended to the case of variable wall thickness cylinders, where the thickness variation is symmetrical about the axis of the cylinder.
Case study of bird streamer caused transient earth faults on a 275KV transmission grid.
(2001) Taylor, Paul.; Hoch, Derek A.
This thesis discusses the results of an investigation that was initiated in January 1996 to determine the root cause of the increasing fault trend in respect of transient earth faults on the 275 kV transmission grid in KwaZulu-Natal, South Africa. Historically it was thought that the persistently poor performance of this network was caused by pollution faults. This network was reinsulated with silicone composite insulators, and cane fire as well as veld fire management programmes were introduced. These projects did not result in a consistently decreasing fault trend on this 275 kV transmission grid. The burn marks caused by the power arcs, which were identified in this study, appeared to indicate that air gap breakdown was occurring. Birds were also observed in close proximity to the faulted towers. Consequently it was thought that bird streamers caused the transmission line faults. Welded rod bird guards designed to prevent bird streamer faults were installed on eighteen 275 kV transmission lines. The accumulative length of these transmission lines is 932 km. The implementation of this initiative coincided with a 73% reduction in the total number of transient earth faults. This improvement in performance indicates a strong statistical correlation showing that a large number of the transient earth faults on the transmission grid are related to bird streamers. Bird streamer induced faults were identified by means of the following diagnostic techniques: • Burn mark analysis • Time-of-day analysis Bird streamer line faults have been observed on I string, V string and strain jumper assemblies on the 275 kV power lines. However, on the 400 kV power lines bird streamer faults have only been observed on V string assemblies. Experimental work involved simulated bird streamers and determining the minimum flashover distance for AC system voltages. Electric field measurements by means of a capacitive probe were undertaken at the ground plane. The electric field measurements at the ground plane under bird streamer intrusion confirm that if the streamer is moved away from the live tower hardware, the electric field enhancement at the ground plane decreases below the background streamer propagation field. This case study determined that in order to prevent bird streamer faults the bird streamer must be moved away from the live tower hardware. The distance it must be moved is at least 900 mm for 275 kV power lines and 1 100 mm for 400 kV lines.
Thermal shock and CFD stress simulations for a turbine blade.
(2002) Ganga, Deepak Preabruth.; Govender, Saneshan.
A 2-D CFD / FEM model to simulate thermal stresses in a turbine blade has been set up using the software FLUENT and FIDAP. The model was validated against the data of Bohn et. al. (1995) and was used to simulate 5 test cases. The numerical model was set up for a single Mark II nozzle guide vane (NGV) and utilised the appropriate boundary conditions for the surrounding flow field. A commercially available software code, FLUENT, was used to resolve the flow field, and heat transfer to the blade. The resulting surface temperature profile was then plotted and used as the boundary conditions in FIDAP (a commercial FEM code) to resolve the temperature and stress profile in the blade. An additional solver within FLUENT essentially superimposes an additional flow field as a result of the NGV vibration in the flow field. The pressure, temperature and heat transfer coefficient distribution, from FLUENT, were compared to those from Bohn et. al. (1995). The model predicted the distributions trends correctly, with an average over-prediction for temperature, of 10 % on the suction side and 6 % on the pressure side. This was restricted to the region from leading edge to 40 % chord on both sides of the blade. The blade temperature and equivalent stress contour trends were also correctly predicted by FIDAP. The blade temperature was over-predicted by and average of 1.7 %, while the equivalent stress magnitude was under-predicted by a worst case of 43 %, but the locations of maximum stress were correctly predicted. The reason for the differences between the stresses predicted by FLUENT / FIDAP and the data given in Bohn et. al. (1995), is believed to be the results of the temperature dependence of the material properties for the blade (ASTM 310 stainless steel), used in the two studies, not being identical. The reasoning behind this argument is because the distribution trends and contour variation, predicted by the model, compared favourably with the data of Bohn et. aI., and only the equivalent stress magnitude differed significantly. This completed the validation of the FLUENT / FIDAP model. The model was used to simulate test cases where temperature (i.e. turbine inlet temperature or TIT), at the model inlet (Le. the pressure inlet boundary in FLUENT), was set up to be time varying. Four simplified cases, viz single shock, multiple shocks, simplified cycle and multiple cycles, and a complex cycle (a mission profile) were simulated. The mission profile represented typical gas turbine operational data. The simulation results showed that stress was proportional to TIT. Changes in TIT were seen at a later time in the stress curve, due to conduction through the blade. Steep TIT changes, such as the shock loads, affected stress later than gentler TIT changes - the simplified and multiple cycles. These trends were consistently seen in the complex cycle. The maximum equivalent stress was plotted against TIT to try and develop a loose law that gives maximum equivalent stress as a function of TIT. A 4th order polynomial was fitted through the maxima and minima of the maximum equivalent stress plot, which gave the maximum and minimum stress as a function of TIT. This function was used calculate the maximum and minimum and mean equivalent stress using the TIT data for the mission profile. Thus, the FLUENT I FIDAP model was successfully validated, used to simulated the test cases and a law relating the equivalent stress as a function of TIT was developed.
Development of the smart aircraft bolt.
(2002) Msibi, L. L.
The work contained herein is in pursuance of the Development of the SMART aircraft bolt. Failure of the bolt in the aircraft wing is taken for granted in the project, and the consequent repairs are presently very costly. The SMART material investigated in this work is the TRIP steel, and any reference to SMART material, in this work, shall at all time mean TRIP steel. Investigation of the stresses pertaining to bolts in general is carried out, based on the bolt theories and using the finite element analysis. An optimal bolt based on impact resistance only has also been suggested. Metallurgical behaviour of materials similar to TRIP materials is also investigated, including a section dedicated only to TRIP steels. Therefore, the work contained herein acts as a good base for further research.
Modular mechatronic CIM control for Internet manufacturing.
(2002) Potgieter, Johan-Gerhard.; Bright, Glen.
Mechatronics encompass a holistic approach to the design, development, production, maintenance and disposal of complex engineering systems, products and processes. The control and modelling of the manufacturing process are carried out in a networked environment allowing for realistic real time control and simulation. This is achieved through the declarative definition of Computer Integrated Manufacturing (CIM) components, the standardisation of CIM interfaces and the object-orientated approach to model development and data management. The development ofthe Modular Mechatronic CIM control system is aimed at intelligently scheduling, controlling and monitoring manufacturing processes in realtime over Internet capable networks. Modular Mechatronics is an alternative design approach that requires the decomposition of a project into separate modules, identifiable by their individual mechatronic functionality. Modular Mechatronic control for Internet manufacturing produces an efficient and effective solution for CIM processes. This approach allows a remote user to monitor and control CIM processes in real time over the Internet allow for a supervisory control structure to control and manage these processes. The modular mechatronic design approach has been applied to the development of the CIM Internet control system, to optimise the overall function ofthe CIM system. A flexible, low cost Modular Mechatronic design approach was used to develop the CIM architecture and computer interface network, which served as the backbone of the Modular Mechatronic CIM control system. The modular designed control system was used to control CIM components in real time over the Internet. The Modular Mechatronic building block development allows for future integration of other CIM components.
A comparative study on the effects of internal vs external pressure for a pressure vessel subjected to piping loads at the shell-to-nozzle junction.
(2003) Maharaj, Ashveer.; Adali, Sarp.; Von Klemperer, Christopher Julian.
This investigation seeks to perform a comparative study between the combined effects of internal pressure and piping loads versus external pressure and piping loads on a pressure vessel. There are currently several well-known and widely-used procedures for predicting the stress situation and the structural stability of pressure vessels under internal pressure when external piping loads (due to thermal expansion, weight, pressure, etc.) are applied at the nozzles. This project familiarises one with several international pressure vessel design Codes and standards, including AS ME (American Society of Mechanical Engineers) pressure vessel code sections and WRC (Welding Research Council) bulletins. It has been found that many vessels are designed to operate under normal or steam-out conditions (in vacuum). The combined effect of the external atmospheric pressure and the piping loads at the nozzle could be catastrophic if not addressed properly - especially when the stability of the structure is a crucial consideration, i.e. when buckling is a concern. The above-mentioned codes and standards do not directly address procedures or provide acceptance criteria for external loads during vacuum conditions. The approach to the study was, firstly, to investigate the effects of internal pressure and piping loads at the shell-to-nozzle junction. Theoretical stresses were compared with Finite Element results generated using the software package MSC PATRAN. Finite Element Methods provide a more realistic approach to the design of pressure vessels as compared to theoretical methods. It was necessary to determine if the theoretical procedures currently used were adequate in predicting the structural situation of a pressure vessel. Secondly, the buckling effects of vessels subjected to external atmospheric pressure and piping loads were also investigated. Buckling of the shell-to-nozzle region was explored with the aid of Finite Element software. The results gained were used to develop appropriate procedures for the design of vessels under external atmospheric pressure and piping loads. The design is such that it indicates if buckling will occur at the shell-to-nozzle junction. These design procedures form the basis for future exploration in this regard.
Crashworthiness modelling of SMC composite materials.
(2003) Selvarajalu, Vinodhan.; Morozov, Evgeny.
The purpose of this research is to make an investigation into the crashworthiness modelling of Sheet Moulding Compound (SMC) composite materials, and to study the response of SMC composite structures under dynamic loading. The primary research objectives are thus to review classical and advanced material failure models, and to perform numerical simulation of the crash of composite structures using already available material models. Additionally, a new material model is to be developed for implementation into a commercially available finite element package. In parallel with the numerical simulation of the crasrung of an SMC composite structure, experimentation is performed which is used as a source of validation and comparison with the simulation. For this purpose a testing regime is introduced, which may be mirrored in simulation. As any material model requires initial experimental inputs, the purpose of experimentation is twofold, with testing required both for the quantification of the required model inputs and the basic material characterisation before simulation may begin, as well as for the proposed validation and comparison after the simulation has been carried out. Thus the design of the testing methodology, as well as the design, selection and fabrication of the testing equipment and the composite specimens and demonstrators, as well the actual testing itself, are necessary secondary requirements of the project. Once the testing regime has been facilitated and carried out, numerical simulation validation using already available composite material models may then be carried out at various levels. The results are then analysed and validated with the resultant justification of a new model being developed. The critical viewpoint to be delivered throughout is the need for theoretical formulations for material modelling to be extensively researched and validated in terms of their implementabilty and practicality, a key analysis seemingly missing in most technical write-ups. Such analyses are performed and discussed here, rughlighting the volume of additional work that is encompassed by such a study.
Virtual prototyping of an articulated dump truck.
(2003) Govender, Deena.; Kaczmarczyk, Stefan.
In the modem automotive industry product times to market are being increasingly compressed. In the earthmoving and construction machine industry this is also true with the manufacturer having to respond to new customer requirements quickly and decisively. Virtual prototyping is a vital tool in the vehicle engineer's armoury, allowing a large portion of developmental investigation to be done on the virtual model with the attendant savings in time and cost and allowing often dangerous manoeuvres to be predicted and investigated prior to actual physical prototype testing. The University of Natal BELL Equipment collaborative effort involves the vehicle dynamics modelling and model validation of a BELL Equipment manufactured B40C Articulated Dump Truck (ADT). The modelling was completed using the multibody system (MBS) simulation software package, ADAMS. Initial modelling and simulation results are presented with specific attention paid to the introduction of valid data for compliant joints in the MBS as well as modelling of the tire. The physical testing of the ADT is also presented as well as a discussion of the data acquisition system. Key results from the physical testing of the ADT are also presented and discussed.
Economic evaluation of a district cooling system incorporating thermal storage.
(2003) Bannerman, Andrew.; Govender, Saneshan.
The following report investigates district cooling systems. This form of technology provides an alternative means of providing cooling. In a traditional cooling system each building would include cooling equipment to serve only that building. District cooling differs in that water is chilled at one location and pumped to two or more buildings. District cooling has many benefits over traditional cooling systems. This report, however, aims to determine the economic benefits (if any) of district cooling systems. The location chosen as a model for this study was the University of Natal (Durban) campus. This campus currently operates a district cooling system serving six buildings. This study is hypothetical in nature, as the cooling system is already finalized and operational. The aim of this dissertation is to answer the question of which would be the more attractive alternative if the University were in a position of having to install a completely cooling system. One of the most important steps in this process is the calculation of cooling loads. The cooling load was estimated for each of the buildings associated with the district cooling system. The LOADEST software package was used to derive these cooling loads. The accuracy of LOADEST software was also validated in this study. The bulk of this report is composed of the preliminary work required to obtain capital and operating costs for cooling systems, including validation of cooling load calculation software. It was felt that this prelimiinary work justified inclusion in the final report to provide accurate representation of the steps taken before any economic evaluation could be reached. The capital and operating costs of the district cooling system and a more traditional system were compared. It was found that the district cooling system reduces operating costs significantly, although it's capital cost is higher than the traditional system against which it was compared.
Accelerated environmental degradation of GRP composite materials.
(2004) Dlamini, Power Madoda.; Von Klemperer, Christopher Julian.; Verijenko, Viktor.
The use of fibre reinforced polymer composites and development of structural composites has expanded rapidly in the Southern African region over the past ten years. The long-term effect of placing these materials outdoors in the Southern African climate is unknown with exposure data for these materials being primarily European and North American based. This study intends to take a broad-based study to the problem of environmental degradation of advanced composite structures. This work is intended to study different degradation mechanisms. Work performed includes: a study of literature on degradation and protective measures; identification of dominant degradation mechanisms; manufacture of specimens; accelerated environmental testing; and an assessment of the effect of the exposure on the chemical properties The goal of this work is to produce information, which can be subsequently used to determine the rate of damage, methods of suitable protection and necessary maintenance intervals for polymer composite components. The approach was: to simulate outdoor exposure within a reduced period of time; to establish correlation of results with actual outdoor exposure; and to determine how the gel coats compare with other protective methods. As part of the objectives of the study (i.e. to assess the durability of polymer matrix composites materials subjected to environmental exposure), an experimental study was carried out to establish the durability of specific gel coats against ultraviolet (DV) and moisture degradation. An investigation of the effectiveness of the various protective measures has begun with a review of selected gel coats available as a protective coating. Laminates with these gel coats have been set up for both accelerated and natural exposure tests. 3000, 2500, 2000, 1600, and 800 hours of accelerated DV exposure tests were performed on polyester GRP laminates with gel coats. No measurable strength loss occurred on protected laminates; there was significant increase in yellowness on un-protected laminates; all protected specimens showed a fair retention of gloss; fibre prominence occurred on unprotected laminates; and the glass transition of samples had dropped from the normal polyester glass transition temperature range.

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