Analysis of rotor eddy current loss and thermal deformation of magnetic liquid double suspension bearing

Magnetic-liquid double suspension bearing(MLDSB)is a new type of suspension bearing based on electromagnetic suspension and supplemented by hydrostatic supporting.Without affecting the electromagnetic suspension force,the hydrostatic supporting effect is increased,and the real-time coupling of magnetic and liquid supporting can be realized.However,due to the high rotation speed,the rotor part produces eddy current loss,resulting in a large temperature rise and large ther-mal deformation,which makes the oil film thickness deviate from the initial design.The support and bearing characteristics are seriously affected.Therefore,this paper intends to explore the internal effects of eddy current loss of the rotor on the temperature rise and thermal deformation of MLDSB.Firstly,the 2D magnetic flow coupling mathematical model of MLDSB is established,and the eddy current loss distribution characteristics of the rotor are numerically simulated by Maxwell software.Secondly,the internal influence of mapping relationship of structural operating parameters such as input current,coil turns and rotor speed on rotor eddy current loss is revealed,and the changing trend of rotor eddy current loss under different design parameters is explored.Thirdly,the eddy cur-rent loss is loaded into the heat transfer finite element calculation model as a heat source,and the temperature rise of the rotor and its thermal deformation are simulated and analyzed,and the influ-ence of eddy current loss on rotor temperature rise and thermal deformation is revealed.Finally,the pressure-flow curve and the distribution law of the internal flow field are tested by the particle image velocimetry(PIV)system.The results show that eddy current loss increases linearly with the in-crease of coil current,coil turns and rotor speed.The effect of rotational speed on eddy current loss is much higher than that of coil current and coil turns.The maximum temperature rise,minimum temperature rise and maximum thermal deformation of the rotor increase with the increase of eddy current loss.The test results of flow-pressure and internal trace curves are basically consistent with the theoretical simulation,which effectively verifies the correctness of the theoretical simulation.The research results can provide theoretical basis for the design and safe and stable operation of magnetic fluid double suspension bearings.

Study on the effect of thermal deformation on the liquid seal of high-temperature molten salt pump in molten salt reactor

The high-temperature molten salt pump is the core equipment in a molten salt reactor that drives the flow of the molten salt coolant.Rotor stability is key to the continuous and reliable operation of the molten salt pump,and the liquid seal at the wear ring can affect the dynamic characteristics of the rotor system.When the molten salt pump is operated in the hightemperature molten salt medium,thermal deformation of the submerged parts inevitably occurs,changing clearance between the stator and rotor,affecting the leakage and dynamic characteristics of the seal.In this study,the seal leakage,seal dynamic characteristics,and rotor system dynamic characteristics are simulated and analyzed using finite element simulation software based on two cases of considering the effect of seal thermal deformation effect or not.The results show a significant difference in the leakage characteristics and dynamic characteristics of the seal obtained by considering the effect of seal thermal deformation and neglecting the effect of thermal deformation.The leakage flow rate decreases,and the first-order critical speed of the seal-bearing-rotor system decrease after considering the seal’s thermal deformation.

Incompatible thermal deformation of interlayers and corresponding damage mechanism of high-speed railway track structure

In the service period,the instability of ballastless track bed are mostly related to the damage of interlayers which are mainly resulted from the incompatible thermal deformation of interlayers.The temperature field within the ballastless track bed shows significant non-uniformity due to the large difference in the materials of various structure layers,leading to a considerable difference in the force bearing of different structure layers.Unit Ballastless Track Bed(UBTB)is most significantly affected by temperature gradient.The thermal deformation of interlayers within UBTB follows the trend of ellipsoid-shape buckling under the effect of the temperature gradient,resulting in a variation of the contact relationship between structure layers and a significant periodic irregularity on the rail.When the train travels on the periodically irregular rail,the structure layers are locally contacted,and the contact zone moves with the variation of the wheel position.This wheel-followed local contact greatly magnifies the interlayer stress,causes interlayer damage,and leads to a considerable increase in the bending moment of the track slab.Continuous Ballastless Track Bed(CBTB)is most significantly affected by the overall temperature variation,which may cause damage to the joint in CBTB.Under the combined action of the overall temperature rise and the temperature gradient,the interlayer damage continuously expands,resulting in bonding failure between structural layers.The thermal force in the continuous track slabs will cause the up-heave buckling and the sudden large deformation of the track slab,and the loss of constraint boundary of the horizontal stability.For the design of a ballastless track structure,the change of bearing status and structural damage related to the incompatible thermal deformation of interlayers should be considered.

Experiments and Simulation of Thermal Behaviors of the Dual-drive Servo Feed System

The machine tool equipped with the dual-drive servo feed system could realize high feed speed as well as sharp precision. Currently, there is no report about the thermal behaviors of the dual-drive machine, and the current research of the thermal characteristics of machines mainly focuses on steady simulation. To explore the influence of thermal characterizations on the precision of a jib boring machine assembled dual-drive feed system, the thermal equilibrium tests and the research on thermal-mechanical transient behaviors are carried out. A laser interferometer, infrared thermography and a temperature-displacement acquisition system are applied to measure the temperature distribution and thermal deformation at different feed speeds. Subsequently, the finite element method （FEM） is used to analyze the transient thermal behaviors of the boring machine. The complex boundary conditions, such as heat sources and convective heat transfer coefficient, are calculated. Finally, transient variances in temperatures and deformations are compared with the measured values, and the errors between the measurement and the simulation of the temperature and the thermal error are 2 ~C and 2.5 pm, respectively. The researching results demonstrate that the FEM model can predict the thermal error and temperature distribution very well under specified operating condition. Moreover, the uneven temperature gradient is due to the asynchronous dual-drive structure that results in thermal deformation. Additionally, the positioning accuracy decreases as the measured point became further away from the motor, and the thermal error and equilibrium period both increase with feed speeds. The research proposes a systematical method to measure and simulate the boring machine transient thermal behaviors.

Thermal Influence of the Couette Flow in a Hydrostatic Spindle on the Machining Precision

Hydrostatic spindles are increasingly used in precision machine tools. Thermal error is the key factor affecting the machining accuracy of the spindle, and research has focused on spindle thermal errors through examination of the influence of the temperature distribution, thermal deformation and spindle mode. However, seldom has any research investigated the thermal effects of the associated Couette flow. To study the heat transfer mechanism in spindle systems, the criterion of the heat transfer direction according to the temperature distribution of the Couette flow at different temperatures is deduced. The method is able to deal accurately with the significant phenomena occurring at every place where thermal energy flowed in such a spindle system. The variation of the motion error induced by thermal effects on a machine work-table during machining is predicated by establishing the thermo-mechanical error model of the hydrostatic spindle for a high precision machine tool. The flow state and thermal behavior of a hydrostatic spindle is analyzed with the evaluated heat power and the coefficients of the convective heat transfer over outer surface of the spindle are calculated, and the thermal influence on the oil film stiffness is evaluated. Thermal drift of the spindle nose is measured with an inductance micrometer, the thermal deformation data 1.35 μm after running for 4 h is consistent with the value predicted by the finite element analysis’s simulated result 1.28 μm, and this demonstrates that the simulation method is feasible. The thermal effects on the processing accuracy from the flow characteristics of the fluid inside the spindle are analyzed for the first time.

Simulation and experiment analysis on thermal deformation of tool system in single-point diamond turning of aluminum alloy

The aim of this work is to simulate thermal deformation of tool system and investigate the influence of cutting parameters on it in single-point diamond turning(SPDT) of aluminum alloy. The experiments with various cutting parameters were conducted. Cutting temperature was measured by FLIR A315 infrared thermal imager. Tool wear was measured by scanning electron microscope(SEM). The numerical model of heat flux considering tool wear generated in cutting zone was established. Then two-step finite element method(FEM) simulations matching the experimental conditions were carried out to simulate the thermal deformation. In addition, the tests of deformation of tool system were performed to verify previous simulation results. And then the influence of cutting parameters on thermal deformation was investigated. The results show that the temperature and thermal deformation from simulations agree well with the results from experiments in the same conditions. The maximum thermal deformation of tool reaches to 7 μm. The average flank wear width and cutting speed are the dominant factors affecting thermal deformation, and the effective way to decrease the thermal deformation of tool is to control the tool wear and the cutting speed.

Study on the influence of three-grid assembly thermal deformation on breakdown times and an ion extraction process

In order to study the influence of three-grid assembly thermal deformation caused by heat accumulation on breakdown times and an ion extraction process,a hot gap test and a breakdown time test are carried out to obtain thermal deformation of the grids when the thruster is in 5 k W operation mode.Meanwhile,the fluid simulation method and particle-in-cell-Monte Carlo collision（PICMCC） method are adopted to simulate the ion extraction process according to the previous test results.The numerical calculation results are verified by the ion thruster performance test.The results show that after about 1.2 h operation,the hot gap between the screen grid and the accelerator grid reduce to 0.25–0.3 mm,while the hot gap between the accelerator grid and the decelerator grid increase from 1 mm to about 1.4 mm when the grids reach thermal equilibrium,and the hot gap is almost unchanged.In addition,the breakdown times experiment shows that 0.26 mm is the minimal safe hot gap for the grid assembly as the breakdown times improves significantly when the gap is smaller than this value.Fluid simulation results show that the plasma density of the screen grid is in the range 6？×10^（17）–6？×？10^（18） m^（13） and displays a parabolic characteristic,while the electron temperature gradually increases along the axial direction.The PIC-MCC results show that the current falling of an ion beam through a single aperture is significant.Meanwhile,the intercepted current of the accelerator grid and the decelerator grid both increase with the change in the hot gap.The ion beam current has optimal perveance status without thermal deformation,and the intercepted current of the accelerator grid and the decelerator grid are 3.65 m A and 6.26 m A,respectively.Furthermore,under the effect of thermal deformation,the ion beam current has over-perveance status,and the intercepted current of the accelerator grid and the decelerator grid are 10.46 m A and 18.24 m A,respectively.Performance test results indicate that the breakdown times increase obviously.The intercepted current of the accelerator grid and the decelerator grid increases to 13 m A and 16.5 m A,respectively,due to the change in the hot gap after 1.5 h operation.The numerical calculation results are well consistent with performance test results,and the error comes mainly from the test uncertainty of the hot gap.

Adaptive Shape Control for Thermal Deformation of Membrane Mirror with In-plane PVDF Actuators

Optical membrane mirrors are promising key components for future space telescopes. Due to their ultra-thin and high flexible properties, the surfaces of these membrane mirrors are susceptible to temperature variations. Therefore adaptive shape control of the mirror is essential to maintain the surface precision and to ensure its working performance. However, researches on modeling and control of membrane mirrors under thermal loads are sparse in open literatures. A 0.2 m diameter scale model of a polyimide membrane mirror is developed in this study. Three Polyvinylidene fluoride(PVDF) patches are laminated on the non-reflective side of the membrane mirror to serve as in-plane actuators. A new mathematical model of the piezoelectric actuated membrane mirror in multiple fields,(i.e., thermal,mechanical, and electrical field) is established, with which dynamic and static behaviors of the mirror can be analyzed.A closed-loop membrane mirror shape control system is set up and a surface shape control method based on an influence function matrix of the mirror is then investigated. Several experiments including surface displacement tracking and thermal deformation alleviation are performed. The deviations range from 15 μm to 20 μm are eliminated within 0.1 s and the residual deformation is controlled to micron level, which demonstrates the effectiveness of the proposed membrane shape control strategy and shows a satisfactory real-time performance. The proposed research provides a technological support and instruction for shape control of optical membrane mirrors.

Iterative reverse deformation optimization design of castings based on numerical simulation of solidification thermal stress

In the casting process,in order to compensate for the solidification shrinkage to obtain higher dimensional accuracy of the casting,it is often necessary to modify the original design of castings,and a suitable compensation method has a decisive impact on the dimensional accuracy of the actual casting.In this study,based on solidification simulation,a design method of reverse deformation is proposed,and two compensation methods,empirical compensation and direct reverse deformation,are implemented.The simulation results show that the empirical compensation method has problems such as difficulty in determining the parameters and satisfaction of both the overall and local accuracy at the same time;while based on the simulation results for each node of the casting,the direct reverse deformation design achieves the design with shape.In addition,the casting model can be optimized through iterative revisions,so that higher dimensional accuracy can be continuously obtained in the subsequent design process.Therefore,the direct reverse deformation design is more accurate and reasonable compared to empirical compensation method.

Practical Calculation of Thermal Deformation and Manufacture Error in Surface Grinding

The paper submits a method to calculate thermal deformation and manufacture error in surface grinding. The author established a simplified temperature field model, and derived the thermal deformation of the ground workpiece. It is found that there exists not only a upwarp thermal deformation, but also a parallel expansion thermal deformation. A upwarp thermal deformation causes a concave shape error on the profile of the workpiece, and a parallel expansion thermal deformation causes a dimension error in height. The calculations of examples are given and compared with presented experiment data.

Microstructural changes during heating of super duplex stainless steel and its thermal deformation behavior

Microstructural changes during heating of highly alloyed Cr26Ni7 type super duplex stainless steel （SDSS2607） and its thermal deformation behavior were investigated. At different heating rates, the mechanism of phase transition from y phase to 6 phase and growth modes of ~ phase differed. Variations in microstructures for as- cast SDSS2607 during heat preservation at 1 220 ~C indicated two kinds of transformations from y phase to 6 phase. In-situ observations of microstructural changes during the tensile process at 1 050 showed a mutual coordination between y and 6 phases. When the true strain increased, the mutual coordination between 7 and 6 phases was damaged. Subsequently, cracks nucleated at the ＂y/g interface. With the increase in temperature, the strength of as- cast SDSS2607 decreased while its plasticity increased. Its thermoplasticity was poor, and the reduction in area of tensile specimens was less than 80%. When the deformation strain of hot compression increased, the stable deformation zone in the heat processing maps enlarged gradually. Moreover, the unstable deformation zones were extended.

Motion Track Modeling and Analysis of Belt Spindle under Combined Effects of Bending Moment-Torque-Thermal Deformation

The motion track of belt spindle is important for the radial error of belt spindle. An analytical modeling method for the motion track of belt spindle under the combined effects of bending moment-torque-thermal deformation is proposed in this paper. Three running phases of belt spindle have been analyzed and modeled: the start-up phase with leaping change due to the change in force and bending moment, the accelerating phase with axis deflection, and the constant speed phase with axis regression because of the combined effects of bending moment-torque-thermal deformation. The simulation and test were completed on the belt spindle of SKVM850 machine tool, which illustrates the variation law of the radial error of belt spindle during the whole running phases.

STUDY OF THERMAL DEFORMATION OF MICROELECTRONICS PACKAGING PRODUCT BY INTERFEROMETRIC TECHNIQUE

In this paper, the out-of-plane deformation of silicon surface of Direct Chip Attachment (DCA) assembly, under thermal loading, was measured in real-time by Twyman/Green interferometry. The contour maps of the out-of-plane displacement fields of silicon surface under thermal loading and cycling of various temperature were obtained, Experimental results show that the relation between the out-of-plane displacement and temperature is nonlinear and varies with temperature cycling, due to nonlinear mechanical behavior of the materials used in electronic packaging. A comparison of the aut-of-plane displacement Gelds of silicon surface measured by T/G interferometry in real-time and replicating technique of high temperature specimen grating of moire interferometry was made.

Diagnosis of the Thermal Bow of a Shaft in a Three Stage Centrifugal Compressor

In practice many turbo-machines driven by motors are started up tooperational speed within a very short time, i. e. in less than 20 seconds. For this type of machinesthe compatibility of thermal deformation of the rotor structure must be taken into account in themachine design, or the thermal deformation will be constrained and a huge resultant force can causethe shaft bending and consequently resulting in violent vibrations. In this paper, detection ofthermal bow of a shaft in a three stage centrifugal compressor in a petrochemical plant ispresented. The diagnostic results show that the thermal bow was induced by the incompatibility ofaxial thermal deformation of the rotor structure. A remedial action allowing free axial thermalexpansion of the outer parts of the rotor is suggested.

Thermal deformation analysis of the composite material satellite antenna

Controlling the thermal deformation is a crucial index for the design of the satellite antenna. To calculate and measure the satellite antenna’s thermal deformation is also an important step for the design of satellite antenna. Based on the foundation of equivalent assumption, the thermal deformation of the parabolic satellite antenna was analyzed by the finite element method for different design project. The best design project that had the minimum of the thermal deformation could be obtained through changing the lay-angle, lay-layers and lay-thickness of each layer. Results show the asymmetry structure has the minimum of thermal deformation. This paper may provide useful information for the further investigation on the coupling of thermal-stress structure.

Thermal Expansion and Deformation of Graphene

Taking into consideration short-atomic-range interactions and anharmonic effects, we calculate the thermal ex- pansion coefficients, Gruneisen parameters, the elastic modulus of graphene varying with temperature and the phonon frequency. The anharmonic effects associated with the graphene deformation are also discussed. The results show that the value of thermal expansion coefficient is negative in the moderate temperature range, and it becomes positive when the temperature grows to be higher than a certain value. The change rate of elastic modulus with respect to temperature and pressure are calculated, and phonon frequencies are estimated. In the process of graphene thermal expansion, it is accompanied with the change of bond length and the rotation around the axis normal to the plane. Our results indicate that the effects due to the bond change are more significant than that of the rotation. We also show that if anharmonic effects are ignored, the thermal expansion coefficient and the Gruneisen parameters are zero, and the elastic modulus and the phonon frequency are constant. If anharmonic effects are considered up to the second term, these values will vary with temperature, and become closer to the experimental value. The higher the temperature is, the more significant the anharmonic effects become.

Surface registration algorithm for rapid detection of surface thermal deformation of paraboloid antennas

In order to obtain and master the surface thermal deformation of paraboloid antennas,a fast iterative closest point( FICP) algorithm based on design coordinate guidance is proposed,which can satisfy the demands of rapid detection for surface thermal deformation. Firstly,the basic principle of the ICP algorithm for registration of a free surface is given,and the shortcomings of the ICP algorithm in the registration of surface are analysed,such as its complex computation,long calculation time,low efficiency,and relatively strict initial registration position. Then an improved FICP algorithm based on design coordinate guidance is proposed. Finally,the FICP algorithm is applied to the fast registration test for the surface thermal deformation of a paraboloid antenna. Results indicate that the approach offers better performance with regard to fast surface registration and the algorithm is more simple,efficient,and easily realized in practical engineering application.

Mechanical properties and thermal deformation behavior of low-cost titanium matrix composites prepared by a structure-optimized Y_(2)O_(3) crucible

A porous yttrium oxide crucible with both thermal shock resistance and erosion resistance was developed by structural optimization.The structure-optimized yttrium oxide crucible was proved to be suitable for melting highly reactive titanium alloys.Low-cost(TiB+Y2O_(3))-reinforced titanium matrix composites were prepared by vacuum induction melting using the prepared crucible.The thermal deformation behavior and microstructure evolution of(TiB+Y2O_(3))-reinforced tita-nium matrix composites were investigated at deformation temperatures of 900-1100℃with strain rates of 0.001-1 s-1.The results showed that the prepared yttrium oxide crucible had both thermal shock and erosion resistance,the low-cost titanium matrix composites could be prepared by the developed yttrium oxide crucibles which were homogeneous in composition and highly sensitive to strain rate and deformation temperature,and the peak and theological stresses decreased with increasing deformation temperature or decreasing strain rate.In addition,the average thermal deformation activation energy of the composites was calculated to be 574.6 kJ/mol by establishing the Arrhenius constitutive equation in consideration of the strain variables,and the fitting goodness between the predicted stress value and the measured value was 97.624%.The calculated analysis of the hot processing map showed that the best stable thermal deformation zone was located in the deformation temperature range of 1000-1100℃and strain rate range of 0.001-0.01 s^(-1),where the peak dissipation coefficient wasη=71%.In this zone,the deformation of the reinforcement and matrix was harmonious,the reinforcement was less likely to fracture,dynamic recrystallization occurred more fully and the alloy exhibited near steady rheological characteristics.

Study on seepage and deformation characteristics of coal microstructure by 3D reconstruction of CT images at high temperatures

To study the seepage and deformation characteristics of coal at high temperatures,coal samples from six different regions were selected and subjected to computed tomography(CT)scanning studies.In conjunction with ANSYS software,3 D reconstruction of CT images was used for the establishment of fluidsolid conjugate heat transfer model and coal thermal deformation model based on the microstructures of coal.In addition,the structure of coal was studied in 2 D and 3 D perspectives,followed by the analysis of seepage and deformation characteristics of coal at high temperatures.The results of this study indicated that porosity positively correlated with the fractal dimension,and the connectivity and seepage performances were roughly identical from 2 D and 3 D perspectives.As the porosity increased,the fractal dimension of coal samples became larger and the pore-fracture structures became more complex.As a result,the permeability of coal samples decreased.In the meantime,fluid was fully heated,generating high-temperature water at outlet.However,when the porosity was low,the outlet temperature was very high.The average deformation of coal skeleton with different pore-fracture structures at high temperatures showed a trend of initial increase and subsequent decrease with the increase of porosity and fractal dimension.The maximum deformation of coal skeleton positively correlated with connectivity but negatively correlated with the fractal dimension.

Hot compression deformation behavior of the Mg-Al-Y-Zn magnesium alloy

The hot deformation behavior of a Mg-Al-Y-Zn magnesium alloy was investigated by hot compressive testing on a Gleeble-1500 thermal simulator at the temperature ranging from 523 to 673 K with the strain rate varying from 0.001 to 1 s^-1. The relationships among flow stress, strain rate, and deformation temperature were analyzed, and the deformation activation energy and stress exponent were calculated. Microstructure evolution of the alloy under different conditions was examined. The results indicated that the maximum value of the flow stress increased with the decrease of deformation temperature or the increase of strain rate. Under the present deformation conditions, dynamic recrystallization （DRX） occurred in the alloy, which was the main softening mechanism during deformation at elevated temperature. The deformation temperature and strain had significant effects on the microstructure of the alloy.