This paper presents the finite element model developed for the simulation of pipe elbow production by the so-called ‘Hamburg process’ in order to improve productivity and resource efficiency. To optimize the tooling design, a sensitivity analysis of the tool parameters that influence the quality of pipe elbows, such as mandrel height and length, is conducted. Different materials data sets including damage models were considered. Using numerical simulations, it is possible to determine an optimized tool geometry for the production of specific pipe elbow dimensions. Furthermore, as a result of the experiments and numerical simulations conducted, it is possible to increase the production velocity of the serial plant. Along with deformation, damage models are included in simulations in order to identify the right process boundaries. Finally, an experimentally validated model is developed for increasing resource efficiency in pipe elbow fabrication.
Goal of this work is to homogenize properties of three-cathode plasma sprayed coatings on basis of advanced diagnostics and numerical simulations. After a brief description of the general approach to achieve this objective, selected aspects of the current work are presented. Thereby the paper is focused on the self developed suspension injection TriplexII setup, in the special determination of the plasma and in measurement plus presentation of the suspension-particle-behavior. In the suspension plasma diagnostic part (CT-Computed Tomography) the different temperature profiles and geometries are shown and discussed. Additional the suspension-particle-behavior are more explained with the PIV (Particle Image Velocimetry), High-Speed-Camera and AccuraSpray-g3 results, which are calculated and presented with special image processing algorithm. The last part of the paper describes the suspension coating analysis and concludes with an outlook for future measurements of the self developed SPS-TriplexII setup.
In order to homogenize the properties of APS sprayed coatings, the spray process was investigated using numerical simulations combined with innovative diagnostic techniques. The process was subdivided into three areas: the plasma torch, the free jet, and coating formation. By simulating these areas separately and combining the results, appropriate process parameters for homogenized coatings were obtained. For a comprehensive computation of coating formation which, besides the impact, flattening, and solidification of particles, includes the mechanical properties of the coating, a volume of fluid algorithm is coupled with a finite element model. In order to verify the modeling of the plasma jet and to provide input data for the coating formation, diagnostic efforts were concentrated on measuring the gas temperature of the plasma as well as particle shape, velocity, and temperature. The results of spatially resolved 3D analysis employing an innovative tomography system are presented and compared with the numerical results.
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