Pressure drop (p) and collection efficiency (η) are used to evaluate the separation performance of the cyclone separator. In this study, we conducted comparative study of cyclone models using response surface methodology (RSM), back propagation neural network (BPNN), and group method of data handling (GMDH) networks to develop optimal predictive cyclone models. Also, we conducted multi-objective optimization for maximizing model and minimizing model using genetic algorithm (GA). CFD was performed instead of experimental method to get the estimated values for modeling of p and η. The validation results of CFD showed 0.5% and 2% errors for p and η, respectively, compared with the experimental data. Second, design of experiment (DOE) analysis for 10 cyclone geometrical parameters was executed to obtain the significant geometrical parameters. Vortex finder diameter D x , inlet width a, inlet height b and cone height H co have a significant effect on η and p. However, interaction effects between the geometrical parameters have small effects. The cyclone models by RSM, BPNN and GMDH based on 25 CFD training set were developed. The predictive performance results by the cyclone models were compared by 25 CFD test set. The GMDH method achieved the best prediction for p (R 2 = 99.7, RMSE = 0.102) R 2 adjusted = 98.99, RMSE = 0.0119) than the RSM, BPNN cyclone models. Additionally, uncertainty analysis was performed to estimate the quantitative performance of cyclone models. The results show that the uncertainty width of GMDH models achieved the best prediction (η: ±0.0065, p: ±0.0188). Finally, GA was applied to optimize the GMDH models simultaneously. GA generated 70 non-dominant solutions. Reproducibility of five optimal points was validated by using CFD. The trade-off optimal point showed improvement by 24.31%, 18% and 8.79% for p d 50 and η, respectively.
The thickness distribution of thermoformed products is greatly affected by the viscoelastic behavior of the extruded polymer sheet. In this work, linear and nonlinear rheological experiments are carried out to characterize the viscoelastic properties of acrylonitrile-butadiene-styrene sheets under thermoforming conditions including a wide range of temperatures, strains, and strain rates. First, aspects of linear viscoelasticity such as the storage modulus and loss modulus are measured by small-amplitude oscillatory shear experiments. The discrete relaxation spectra and the Williams-Landel-Ferry parameters are obtained from the constructed linear master curves. Then, nonlinear time-dependent extensional viscosity is measured by uniaxial extensional experiments. The parameters of the damping function are evaluated using an optimization method. In addition, the effect of the orientation of the polymer is analyzed. The uniaxial extensional stress and viscosity in the extruder direction demonstrate higher resistance against tearing and extreme thickness reduction during processing. Finally, the linear and nonlinear input parameters for the numerical simulation are prepared. Numerical simulations are performed using the Wagner model with the obtained nonlinear viscoelasticity. The thickness distribution in thermoformed ABS sheets, obtained numerically, shows good agreement with the experimentally obtained values.
This study investigated an influence of the temperature field on thickness distribution of thermoformed products using complex and high-aspect-ratio mold. The optimum temperature field was obtained to achieve a more uniform thickness distribution in the thermoformed products by using finite element simulation. The material properties of acrylonitrile-butadiene-styrene (ABS) polymer sheet were obtained by two rheological measurement tests. The linear viscoelastic properties, such as the storage modulus and loss modulus, were measured by a small amplitude oscillatory shear (SAOS) test for wide ranges of frequency and temperature. The discrete relaxation time and discrete relaxation modulus were obtained by nonlinear regression. The fitting parameters C 1 and C 2 for the WLF model were obtained by curve fitting. The nonlinear viscoelastic property, such as stress relaxation modulus, was measured by a step strain test. The damping function and fitting parameter α of Wagner-Demarmels (WD) model were determined by curve fitting. Then, the Kaye-Bernstein-Kearsley-Zapas (K-BKZ) constitutive equation was utilized to the thermoforming simulation in order to investigate the material behavior of the polymer sheet. The numerical results showed that a more uniform thickness distribution could be achieved with the optimum temperature field of the sheet. The thinnest part of the products was improved by more than 30%.
The size-selective microfluidic separation of glass beads in a curved rectangular microchannel was fabricated in our previous work. In this study, we improve its separation performance and attempt an experimental visualization to examine the separation resolution. In the previous work, we found by visualization that the trajectory of 20 µm glass beads was influenced by their travelling path along a straight inlet channel. Using a forced sheath flow, a consistent bead trajectory along the middle of the straight inlet channel was obtained, and the sheath angle to minimize the focusing width of the flowing distributed beads was determined to be 45°. The physical explanation for the dynamic behavior of microbeads was elaborated. When the ratio of Stokes force to centrifugal force mainly acting on a glass bead fell under unity, the glass bead moved out to the wall in spite of the fact that its size was less than the height of the zero velocity position. To examine the separation resolution, the newly designed size-selective separation microchannel with the sheath was fabricated and its separation performance was visualized. The movement of the glass beads showed a good agreement with the separation mechanism explained by the force ratio. The resolution of the separation was visualized to be 10 µm for the size of glass beads used in the experiment. The size-selective separation performance was explained in terms of physical forces and was improved by solving the previous problems. A cascade device for the continuous separation of microbeads of various sizes can improve the separation resolution.
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