Effects of Shielding Coatings on the Anode Shaping Process during Counter-rotating Electrochemical Machining

Electrochemical machining （ECM） has been widely used in the aerospace, automotive, defense and medical industries for its many advantages over traditional machining methods. However, the machining accuracy in ECM is to a great extent limited by the stray corrosion of the unwanted material removal. Many attempts have been made to improve the ECM accuracy, such as the use of a pulse power, passivating electrolytes and auxiliary electrodes. However, they are sometimes insufficient for the reduction of the stray removal and have their limitations in many cases. To solve the stray corrosion problem in CRECM, insulating and conductive coatings are respectively used. The different implement processes of the two kinds of coatings are introduced. The effects of the two kinds of shielding coatings on the anode shaping process are investigated. Numerical simulations and experiments are conducted for the comparison of the two coatings. The simulation and experimental results show that both the two kinds of coatings are valid for the reduction of stray corrosion on the top surface of the convex structure. However, for insulating coating, the convex sidewall becomes concave when the height of the convex structure is over 1.26 ram. In addition, it is easy to peel off by the high-speed electrolyte. In contrast, the conductive coating has a strong adhesion, and can be well reserved during the whole machining process. The convex structure fabricated by using a conductive iron coating layer presents a favorable sidewall profile. It is concluded that the conductive coating is more effective for the improvement of the machining quality in CRECM. The proposed shielding coatings can also be employed to reduce the stray corrosion in other schemes of ECM.

New Bulb Turbine with Counter-rotating Tandem-runner

With the increasing demand for the clean sustainable power, the turbine design urgently turns to increase the capability significantly toward higher head for generating larger power. Currently, there are many studies in the field of the bulb turbine with single-stage runner, though reports about counter-rotating tandem-runner are rare. However, the further high-head application with the single-stage runner is very difficult to achieve due to the limit of the specific speed. In this paper, a new bulb turbine with the tandem-runner is designed in order to substantially increase the applicable limit toward higher head with larger power. A half of the net head is absorbed by the frontal runner which can generate output power, while the remaining half is absorbed by the rear runner. To generate the Euler energy required for the rear runner, the frontal runner has the counter-rotation against the rear runner so that the counter-rotating tandem-runner can meet the purpose of double head and power under the same size as the conventional bulb turbine. Supply and demand of Euler energy between the two runners are thoroughly optimized through the detailed flow analysis, in order to secure the stable operation. As a result, the interference of Euler energies between the outflow from the frontal runner and the inflow to the rear runner is confirmed to be very small on the counter-rotating interface between the two runners. The prediction method of on-cam performance between the two adjustable runners is also developed numerically, which provides optimal flow between the two runners. This research provides a theoretical basis for the optimal design and operation of the counter-rotating tandem-runner bulb turbines.

Link Resource Allocation in Counter-Rotating Seam of Low-Orbit Satellite Network

This paper studies the communication problem at the counter-rotating seam of the low-orbit satellite based on the walker constellation. The counter-rotating seam has a short life cycle, low capacity, and dynamic geometric parameters. To better utilize the scarce link resources at the seam, increase network throughput, and approach the physical limits of the link throughput at the seam, an initial phase condition that maximizes the relative rotational joint link throughput is calculated. In the experimental simulation results using the Iridium system as an example, it is shown that better throughput can be obtained under the initial conditions, and the throughput is improved by about 30%.

Isolated attosecond pulse generation with few-cycle two-color counter-rotating circularly polarized laser pulses

Most of the schemes for generating isolated attosecond pulses（IAP） are sensitive to the carrier-envelope phase（CEP）of the driving lasers. We propose a scheme for generating IAP using two-color counter-rotating circularly polarized（TCCRCP） laser pulses. The results demonstrate that the dependence of the IAP generation on CEP stability is largely reduced in this scheme. IAP can be generated at most of CEPs. Therefore, the experiment requirements become lower.

Semi-integer harmonic generation from an argon atom by bichromatic counter-rotating circularly polarized laser field

We theoretically investigated the properties of the high-order harmonic generation from an argon atom by bichromatic counter-rotating circularly polarized(BCCP)laser field.The harmonic emission processes have been illustrated by numerically solving the two-dimensional time-dependent Schr¨odinger equation of an atom in intense laser fields.It is found that with the decrease of the right-circularly polarized laser wavelength,the harmonic spectra are gradually splitting and the harmonic orders move towards the higher frequency.Meanwhile,the integer and semi-integer harmonic emission will be generated when the frequency ratios of right-and left-circularly polarized lasers are semi-integer.The emission mechanism of the semi-integer-order harmonics has been investigated by using the rules of photon absorption and emission.

Effects of initial electronic state on vortex patterns in counter-rotating circularly polarized attosecond pulses

We theoretically investigate the effects of different electronic states as the initial state on the vortex patterns in photoelectron momentum distributions(PMDs)from numerical solutions of the two-dimensional(2D)time-dependent Schrodinger equation(TDSE)of He^(+)with a pair of counter-rotating circularly polarized attosecond pulses.It is found that the number of spiral arms in vortex patterns is equal to the number of the absorbed photons when the initial state is the ground state.However,the number of spiral arms in vortex patterns is always two more than the number of the absorbed photons when the initial state is the excited state.This sensitivity is attributed to the initial electron density distribution.In addition,we have demonstrated the PMDs for different initial electronic states with the same wavelengths and analyzed their corresponding physical mechanisms.It is illustrated that the method presented can be employed to effectively control the distribution of the electron vortices.

Power Stabilization System with Counter-Rotating Type Pump-Turbine Unit for Renewable Energy

Traditional type pumped storage system contributes to adjust the electric power unbalance between day and night, in general. The pump-turbine unit is prepared for the power stabilization system, in this serial research, to provide the constant power with good quality for the grid system, even at the suddenly fluctuating/turbulent output from renewable energies. In the unit, the angular momentum changes through the front impeller/runner must be the same as that through the rear impeller/runner, that is, the axial flow at the outlet should be the same to the axial flow at the inlet. Such flow conditions are advantageous to work at not only the pumping mode but also the turbine mode. This work discusses experimentally the performance of the unit, and verifies that this type unit is very effective to both operating modes.

Role of potential on high-order harmonic generation from atoms irradiated by bichromatic counter-rotating circularly polarized laser fields

We investigate high-order harmonic generation from atoms irradiated by bichromatic counter-rotating circularly polarized laser pulses by numerically solving the time-dependent Schrödinger equation.It is found that the minimum energy position of the harmonic spectrum and the non-integer order optical radiation are greatly discrepant for different atomic potentials.By analyzing the quantum trajectory of the harmonic emission,discrepancies among the harmonic spectra from different potentials can be attributed to the action of the potential on the ionized electrons.In addition,based on the influence of the driving light intensity on the overall intensity and ellipticity of higher order harmonics,the physical conditions for generating a high-intensity circularly polarized harmonic can be obtained.

Counter-Rotating Type Horizontal-Axis Bidirectional Propellers for Tidal Stream Power Unit

Tidal stream power units with horizontal-axis propellers are one of promising technologies for generating the renewable green energy. The ebb and flow require that the power unit must operate in bidirectional tidal streams. Hence a tidal stream power unit with counter-rotating type horizontal-axis bidirectional propellers is proposed in this paper. The blades with fully-symmetrical hydrofoils were optimized numerically. The output and flow conditions predicted by the computational fluid dynamics simulations are compared with the results of the wind tunnel experiments at the higher tip speed ratios, which are of expected usual operating conditions of this unit. The numerical and experimental results show good agreements. It is also confirmed that the flow discharged from the counter-rotating type propellers has no swirling component, though the single propeller generates the unacceptable swirling component.

A Numerical Prediction of Tip Vortices from Tandem Propellers in the Counter-Rotating Type Tidal Stream Power Unit

Ocean energy has a potential of providing a large amount of renewable energy around the world. One of the forms of ocean energy, tidal stream power is widely recognized as the continuous, predictable and eco-friendly ocean energy source. Unique tandem propellers that can counter-rotate have been designed to generate electric power effectively from a tidal stream. This type of power unit has several advantages compare to the conventional unit with a single propeller. At the design of the tidal stream power unit, it is important to investigate the structure of the tip vortex tubes shedding to predict the load of the propeller. In this research, we investigated the tip vortex shedding using the CFD method for the conventional single propeller and counter-rotating type tandem propellers and estimated the performance efficiency using RANS (Reynolds Averaged Navier-Stokes) model and we confirmed the limitation of RANS model on the calculation of the tip vortex stretching.

Tomographic particle image velocimetry measurement on three-dimensional swirling flow in dual-stage counter-rotating swirler

Three-Dimensional(3D)swirling flow structures,generated by a counter-rotating dualstage swirler in a confined chamber with a confinement ratio of 1.53,were experimentally investigated at Re=2.3×10^(5)using Tomographic Particle Image Velocimetry(Tomo-PIV)and planar Particle Image Velocimetry(PIV).Based on the analysis of the 3D time-averaged swirling flow structures and 3D Proper Orthogonal Decomposition(POD)of the Tomo-PIV data,typical coherent flow structures,including the Corner Recirculation Zone(CRZ),Central Recirculation Zone(CTRZ),and Lip Recirculation Zone(LRZ),were extracted.The counter-rotating dual-stage swirler with a Venturi flare generates the independence process of vortex breakdown from the main stage and pilot stage,leading to the formation of an LRZ and a smaller CTRZ near the nozzle outlet.The confinement squeezes the CRZ to the corner and causes a reverse rotation flow to limit the shape of the CTRZ.A large-scale flow structure caused by the main stage features an explosive breakup,flapping,and Precessing Vortex Core(PVC).The explosive breakup mode dominates the swirling flow structures owing to the expansion and construction of the main jet,whereas the flapping mode is related to the wake perturbation.Confinement limits the expansion of PVC and causes it to contract after the impacting area.

Performance of Semi-solid Slurry Produced by Twin-screw Stirring Mixer and Rheo-diecasting Process of AZ91D Alloy

The microstructure of semi-solid slurry of AZ91D alloy, which was produced by twin-screw stirring mixer under the different parameters, was investigated.Rheoforming by cold chamber die casting process was performed thereafter. The results indicate that with decreasing of the barrel temperature of the mixer and the pouring temperature of molten Mg alloy, the solid fraction of semi-solid slurry increases and the size of non-dendritic grains becomes smaller. While the shear rate increases, the solid fraction of semi-solid slurry decreases. The tensile strength and elongation of metal rheoformed by die casting are higher by about 37% and 44% respectively than those produced by conventional liquid die casting.

Numerical Simulation of Twin-Screw Extrusion with Wall Slip

Wall slip boundary condition is first introduced into twin-screw extrusion with the Navier slip law. Three-dimensional isothermal flow in the twin-screw extruder is simulated by using the finite element package POLYFLOW. Profiles of velocity contours in the screw channel and shear rate distributions in the intermeshing region are presented for different slip coefficients. Curves of axial pressure difference, average shear rate and dispersive mixing index vs. the slip coefficient are plotted and discussed. Comparisons are also made between the wall slip conditions and the non-slip condition. The simulation results indicate that, as the level of wall slip decreases, the axial pressure difference rises, the shear effect is intensified and the axial mixing is also enhanced. All these flow characteristics seem to level off with the increase of the slip coefficient. However, because of the inherent limitation of the Navier slip law, use of an overestimated slip coefficient would predict an over-sticky state between the screw surface and the polymer melt.

Study on Hardware-in-loop Simulation of Twin-screw Extruder Experiment System

In order to facilitate the teaching of industrial processes and experiments on the twin-screw extruder control debugging,and be closer to the actual testing,to reduce the debugging costs and the risk of debugging process,the paper designs a hardware-in-loop simulation of twin-screw extruder experiment system which is closer to scene,low cost and high safety.The system through the establishment of twin-screw extruder’s mathematical model on computer to simulate the realistic system and there is hardware practicality in the computer simulation loop.The hardware based on C8051F020 can operate in the simulation loop in real time.In computer software design, we desigh man-machine interface that is intuitive and easy to operate,can reflect twin-screw extruder main operation information vividly.Finally,twin-screw extruder’s 3 heater temperature mathematical model and PID incremental control algorithm are presented.

HA/UHMWPE Nanocomposite Produced by Twin-screw Extrusion

The HA/UHMWPE nanocomposite is compounded by twin-screw extrusion of the HA and UHMWPE powder mixture in paraffin oil and then compression molded to a sheet form. TGA measurement shows the HA weight loss after processing is about 1%-2% . FTIR spectra indicate the paraaffin oil residue is trivial and UHMWPE is not oxidized. SEM reveals the HA nano particles are homogeneously dispersed by twin-screw extrusion and the inter-particle spaces are penetrated with UHMWPE fibrils by swelling treatment. HRTEM image indicates the HA particles and UHMWPE are intimately contacted by mechanical interlocking. Compared with the unfilled UHMWPE, stiffness of the composite with the HA volume fraction 0. 23 was significantly enhanced to 9 times without detriment of the yield strength and the ductility.

某散货船单桨、双桨推进系统燃油消耗分析

This paper presents a comparative analysis between single and twin-screw propulsion systems of a bulk carrier to evaluate the ship and propeller performance in terms of fuel consumption as well as to discuss the cavitation and noise criteria.An optimization model is developed to select the optimum propeller geometry and operational point along the engine load diagram for the selected engines of each case.The engines are selected from the same series due to the same behaviour along the engine load diagram.The propellers are selected from the B-series as fixed-pitch propellers.It has been concluded that while the components of the single-screw propulsion system are larger than the twin-screw,the single-screw propulsion system shows a reduction in fuel consumption than the twin screw by around 19%,thus affecting the amount of exhaust emissions from the ship.This model helps the ship designers to select a suitable propeller to improve the energy efficiency of the ships.

Preparation and Characterization of Thermoplastic Starch from Sugar Palm (Arenga pinnata) by Extrusion Method

Sugar palm(Arenga pinnata)starch is considered an important renewable,biodegradable,and eco-friendly polymer,which is derived from agricultural by-products and residues,with great potential for the development of biocomposite materials.This research was aimed at investigating the development of TPS biocomposites from A.pinnata palm starch using an extrusion process.Palm starch,glycerol,and stearic acid were extruded in a twin-screw extruder.Scanning electron microscopy(SEM)analysis of TPS showed that the starch granules were damaged and gelatinized in the extrusion process.The density of TPS was 1.3695 g/mL,lower than that of palm starch,and the addition of stearic acid resulted in increased TPS density.X-ray diffraction(XRD)results showed that palm starch had a C-type pattern crystalline structure.The tensile strength,elongation at break,and modulus of elasticity of TPS were 7.19 MPa,33.95%,and 0.56 GPa,respectively.The addition of stearic acid reduced the tensile strength,elongation at break and modulus of elasticity of TPS.The rheological properties,i.e.,melt flow rate(MFR)and viscosity of TPS,were 7.13 g/10 min and 2482.19 Pa.s,respectively.The presence of stearic acid in TPS resulted in increased MFR and decreased viscosity values.The peak gelatinization temperature of A.pinnata palm starch was 70°C,while Tg of TPS was 65°C.The addition of stearic acid reduced the Tg of TPS.The thermogravimetric analysis(TGA)analysis showed that the addition of glycerol and stearic acid decreased the thermal stability,but extended the temperature range of thermal degradation.TPS derived from A.pinnata palm starch by extrusion method has the potential to be applied in industrial practice as a promising raw material for manufacturing bio-based packaging as a sustainable and green alternative to petroleum-based plastics.

Convex shaping process simulation during counter-rotating electrochemical machining by using the finite element method

In counter-rotating electrochemical machining （CRECM）, a revolving cathode tool with hollow windows of various shapes is used to fabricate convex structures on a revolving part. During this process, the anode workpiece and the cathode tool rotate relative to each other at the same rotation speed. In contrast to the conventional schemes of ECM machining with linear motion of a block tool electrode, this scheme of ECM is unique, and has not been adequately studied yet. In this paper, the finite element method （FEM） is used to simulate the anode shaping process during CRECM, and the simulation process which involves a meshing model, a moving boundary, and a simulation algorithm is described. The simulated anode profiles of the convex structure at different processing times show that the CRECM process can be used to fabricate convex structures of various shapes with different heights. Besides, the variation of the inter-electrode gap indicates that this process can also reach a relative equilibrium state like that in conventional ECM. A rectangular convex and a circular convex are successfully fabricated on revolving parts. The experimental results indicate relatively good agreement with the simulation results. The proposed simulation process is valid for convex shaping prediction and feasibility studies as well.

Investigation of influencing factors of hot streaks migration in high pressure stage of a vaneless counter-rotating turbine

Three-dimensional,viscous,and unsteady CFD simulations have been performed in order to reveal the influencing factors of hot streaks migration in high pressure stage of a vaneless counter-rotating turbine. Based on the numerical results,the comparison between the case with inlet hot streaks and case without inlet hot streaks is carried out,which shows that the effect of inlet hot streaks on the load distributions of high pressure turbine airfoils is not notable and the airfoil load distributions are directly related to the inlet pressure distributions. The predicted results also indicate that the circumferential and radial movements of the hot streaks were not observed in the high pressure turbine stator. This means that the combined effects of secondary flow and buoyancy are very weak in the high pres-sure turbine stator. The numerical results also prove that the circumferential flow angle effect at the inlet of the high pressure turbine rotor,secondary flow effect and buoyancy effect are the mainly influencing factors to directly affect the migration characteristics of the hot streaks in the high pressure turbine rotor.

Experimental investigation on unsteady pressure fluctuation of rotor tip region in high pressure stage of a vaneless counter-rotating turbine

An experimental investigation has been performed to study the unsteady pressure fluctuation of rotor tip region in high pressure stage of a vaneless counter-rotating turbine.The experiment is carried out on a blow-down short duration turbine facility.The investigation indicates that the blow-down short duration turbine facility is capable of substituting continuous turbine facilities in most turbine testing.Through this experimental investigation,a distinct blade-to-blade variation is observed.The results indicate that the combined effects of vane wake,tip leakage flow,complicated wave systems and rotor wake induce the remarkable blade-to-blade variations.The results also show that the unsteady effect is intensified along the flow direction.