04 Fakultät Energie-, Verfahrens- und Biotechnik
Permanent URI for this collectionhttps://elib.uni-stuttgart.de/handle/11682/5
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Item Open Access Enhanced processing of regrind as recycling material in single-screw extruders(2021) Thieleke, Philipp; Bonten, ChristianRegrind processing poses challenges for single-screw extruders due to the irregularly shaped particles. For grooved feed zones, the output is lessened by the reduction of bulk density in comparison to virgin material. Simultaneously, the melt temperature increases, reducing the extruder’s process window. Through experimental investigations on a test stand, a novel feed zone geometry (nominal diameter 35 mm) is developed. It aligns the regrind’s specific throughput with that of virgin material. The regrind processing window is essentially increased. As the solids conveying in the novel feed zone cannot be simulated with existing methods, numerical simulations using the discrete element method are performed. Since plastic deformation occurs in the novel feed zone geometry, a new hysteresis contact model is developed. In addition to spheres, the regrind and virgin particles are modeled as superquadrics to better approximate the irregular shape. The new contact model’s simulation results show excellent agreement with experimental compression tests. The throughput of the extruder simulations is considerably underestimated when using spheres to represent the real particles than when using irregularly shaped superquadrics. Corresponding advantages can be seen especially for virgin material.Item Open Access Process model and life cycle assessment of biorefinery concept using agricultural and industrial residues for biohydrogen production(2024) Gamero, Edgar; Ruppert, Sophia; Miehe, Robert; Sauer, AlexanderSustainable waste management strategies are urgently needed due to an increasing global population and increased waste production. In this context, biorefineries have recently emerged as a promising approach to valorize waste streams and supply a broad range of products. This study presents the process model and life cycle assessment (LCA) of a biorefinery concept using a novel biochemical method, a so-called “dark photosynthesis” conversion. This process is coupled to a photo-fermentation using microalgae. Overall, the biorefinery concept can produce hydrogen, lutein, β-carotene, and proteins for animal feed. Apple pomace from apple juice production is used as feedstock for the primary conversion step. A process model was created with the process simulation software Aspen Plus ® using experimental and literature data. Results from this model were then used in an LCA. The environmental impacts of the proposed biorefinery concept are relatively high, showing the need for process optimization in several areas. Energy system integration, stream recycling, and higher hydrogen yields are recognized as especially important for improving the environmental performance of this concept. Despite these findings, the model shows the feasibility of implementing the biochemical conversion technologies in a biorefinery concept for effectively utilizing residue streams.Item Open Access Automatic joining of electrical components to smart textiles by ultrasonic soldering(2021) Micus, Sebastian; Haupt, Michael; Gresser, Götz T.A suitable connection method to automatically produce E-textiles does not exist. Ultrasonic soldering could be a good solution for that since it works with flux-free solder, which avoids embrittlement of the textile integrated wires. This article describes the detailed process of robot-assisted ultrasonic soldering of e-textiles to printed circuit boards (PCB). The aim is to understand the influencing factors affecting the connection and to determine the corresponding solder parameters. Various test methods are used to evaluate the samples, such as direct optical observation of the microstructure, a peeling tensile test, and a contact resistance measurement. The contact strength increases by reducing the operating temperature and the ultrasonic time. The lower operating temperature and the reduced ultrasonic time cause a more homogeneous metal structure with less defects improving the mechanical strength of the samples.Item Open Access Developing a cloud-based air quality monitoring platform using low-cost sensors(2024) Samad, Abdul; Kieser, Joschka; Chourdakis, Ioannis; Vogt, UlrichConventional air quality monitoring has been traditionally carried out in a few fixed places with expensive measuring equipment. This results in sparse spatial air quality data, which do not represent the real air quality of an entire area, e.g., when hot spots are missing. To obtain air quality data with higher spatial and temporal resolution, this research focused on developing a low-cost network of cloud-based air quality measurement platforms. These platforms should be able to measure air quality parameters including particulate matter (PM10, PM2.5, PM1) as well as gases like NO, NO2, O3, and CO, air temperature, and relative humidity. These parameters were measured every second and transmitted to a cloud server every minute on average. The platform developed during this research used one main computer to read the sensor data, process it, and store it in the cloud. Three prototypes were tested in the field: two of them at a busy traffic site in Stuttgart, Marienplatz and one at a remote site, Ötisheim, where measurements were performed near busy railroad tracks. The developed platform had around 1500 € in materials costs for one Air Quality Sensor Node and proved to be robust during the measurement phase. The notion of employing a Proportional-Integral-Derivative (PID) controller for the efficient working of a dryer that is used to reduce the negative effect of meteorological parameters such as air temperature and relative humidity on the measurement results was also pursued. This is seen as one way to improve the quality of data captured by low-cost sensors.Item Open Access Increasing low-temperature toughness of 09Mn2Si steel through lamellar structuring by helical rolling(2021) Panin, Sergey; Vlasov, Ilya; Moiseenko, Dmitry; Maksimov, Pavel; Maruschak, Pavlo; Yakovlev, Alexander; Gomorova, Julia; Mishin, Ivan; Schmauder, SiegfriedThe aim of the paper was to investigate the helical rolling parameters (a number of passes) for the microstructural modification and the low-temperature impact toughness improvement of the 09Mn2Si High Strength Low-Alloyed (HSLA) steel. In order to achieve this purpose, work spent to crack initiation and propagation was analyzed and compared with patterns of fracture surfaces. The microstructure and impact toughness values were presented in the temperature range from +20 to -70°C. Also, the fracture mechanisms in individual regions on the fracture surfaces were discussed. In addition, a methodology for computer simulation of the process was developed and implemented within the framework of the excitable cellular automata method and its integration with the kinetic theory of fracture. Finally, a theoretical analysis of the effect of grain shapes and orientations on the strain response patterns of a certain meso-volume simulating the material after the helical rolling was carried out.Item Open Access A numerical method for the generation of hierarchical Poisson Voronoi microstructures applied in micromechanical finite element simulations : part I: method(2020) Schneider, Y.; Weber, U.; Wasserbäch, W.; Zielke, R.; Schmauder, S.; Tillmann, W.Poisson Voronoi (PV) tessellations as artificial microstructures are widely used in investigations of material deformation behaviors. However, a PV structure usually describes a relative homogeneous field. This work presents a simple numerical method for generating 2D/3D artificial microstructures based on hierarchical PV tessellations. If grains/particles of a phase cover a large size span, the concept of “artificial phases” can be used to create a more realistic size distribution. From case to case, detailed microstructural features cannot be directly achieved by commercial or free softwares, but they are necessary for a deep or thorough study of the material deformation behavior. PV tessellations created in our process can fulfill individual requirements from material designs. Another reason to use PV tessellations is due to the limited experimental data. Concerning the application of PV microstructures, four examples are given. The FE models and results will be presented in consecutive works, i.e. “part II: applications”.Item Open Access A physically based material model for the simulation of friction stir welding(2020) Panzer, Florian; Shishova, Elizaveta; Werz, Martin; Weihe, Stefan; Eberhard, Peter; Schmauder, SiegfriedA physically based material model, taking into account the interdependence of material microstructure and yield strength, is presented for an Al 5182 series aluminum alloy for the simulation of friction stir welding using continuum mechanics approaches. A microstructure evolution equation considering dislocation density and grain size is used in conjunction with a description of yield stress. In order to fit experimental stress-strain curves, obtained from compression tests at various strain rates and temperatures, phenomenological relationships are developed for some of the model parameters. The material model is implemented in smoothed particle hydrodynamic research code as well as in the commercial finite element code Abaqus. Simulations for various strain rates and temperatures were performed and compared with experimental results as well as between the two discretization methods in order to verify the material model and the implementation. Simulations provide not only an accurate approximation of stress based on temperature, strain rate, and strain but also an improved insight into the microstructural evolution of the material.Item Open Access Development of a novel method and apparatus for analysis of die dynamics of an isothermal thermoset pultrusion process(2021) Selvarayan, Sathis Kumar; Gresser, Götz T. (Prof. Dr.-Ing.)Pultrusion is a continuous process to manufacture constant cross-sectional fibre reinforced composite profiles. The profiles take their shape as the continuously moving fibre-matrix combination consolidates inside the cavity of a pultrusion die. The temperature-induced viscosity and volumetric changes of the fibre-matrix during the consolidation as well as the friction between the die wall and the moving fibre-matrix generates shear and normal forces that act on the die wall - phenomena known as “die dynamics”. Quantification and analysis of the die dynamics are crucial to understand and control the pultrusion process. However, state-of-the-art methods available to characterise the pultrusion process have limited capability to record the forces that act on the die wall at each position along the length of the pultrusion die. Further, the on-line measurement techniques demand full-scale pultrusion line which, in general, are resource intensive. In addition, the available methodologies have not considered the impact of process additives on the die dynamics. This research work, therefore, focuses on developing a resource-efficient offline testing method to characterise the die dynamics of a thermoset pultrusion process and to pre-determine the required process parameters for a given fibre-matrix combination. In the newly developed approach, called rotating core method, pre-impregnated rovings wound on a solid core with defined fibre volume fraction rotates about the axis of the core inside a hollow cylindrical heated die. The rotational velocity of the rotating core is set to be identical to the line speed of the pultrusion process. The rotating fibre-matrix undergo temperature-induced polymerisation leading to the transformation of the fibre-matrix into a solid composite within the cylindrical die. This mimic the dominant phenomena that occur inside a pultrusion die in the pultrusion process. An apparatus developed within the scope of this work, the Die Dynamics Simulator (DDS), for the first time allows to continuously measure the torque exerted by the rotating fibre-matrix on the DDS die during the polymerisation process. The measured torque represents the resistive forces that arise within the die during the consolidation of the fibre-matrix combination. Evaluation of the curing kinetics and rheology of the resin formulations facilitates the characterisation of their polymerisation behaviour enabling identification of the components of the resistive forces. Further, this work investigates the influence of the following parameters on die dynamics using the developed apparatus: (1) die temperature, (2) velocity of the fibre-matrix, (3) contact area of the die and the fibre-matrix, (4) part thickness, (5) fibre volume fraction, and (6) process additive - internal mould release (IMR). Subsequently, the developed methodology is validated against the pultrusion process using a lab-scale pultrusion line. The results show the dependency of the resistive forces on the individual and the interactions between multiple parameters. More importantly, the experiments conducted with varying concentrations of IMR permitted to evaluate the implication of the mould release on the evolving resistive forces within the die. The results further provide insight at which phase of the polymerising matrix is the IMR most effective. Comparison of the measured forces on the DDS and from that measured on the pultrusion line show good fit for higher fibre volume fractions of the consolidated composite.Item Open Access Performance evaluation of wire cloth micro heat exchangers(2020) Fugmann, Hannes; Martens, Sebastian; Balzer, Richard; Brenner, Martin; Schnabel, Lena; Mehring, CarstenThe purpose of this study is to validate a thermal-hydraulic simulation model for a new type of heat exchanger for mass, volume, and coolant/refrigerant charge reduction. The new heat exchanger consists of tubes with diameters in the range of 1 mm and wires in the range of 100 μm, woven together to form a 200×200×80 mm3 wire cloth heat exchanger. Performance of the heat exchanger has been experimentally evaluated using water as inner and air as outer heat transfer medium. A computational thermal and fluid dynamic model has been implemented in OpenFOAM®. The model allows variation of geometry and operating conditions. The validation of the model is based on one single geometry with an opaque fabric and air-side velocities between 1 and 7 m/s. The simulated and measured pressure drops are found to be in good agreement with a relative difference of less than 16%. For the investigated cases, the effective heat transfer coefficients are in very good agreement (less than 5%) when adapting the contact resistance between tubes and wires. The numerical model describes the fluid flow and heat transfer of the tested heat exchanger with adequate precision and can be used for future wire cloth heat exchanger dimensioning for a variety of applications.Item Open Access Material monitoring of a composite dome pavilion made by robotic coreless filament winding(2021) Mindermann, Pascal; Rongen, Bas; Gubetini, Drilon; Knippers, Jan; Gresser, Götz T.A hemispherical research demonstration pavilion was presented to the public from April to October 2019. It was the first large-scale lightweight dome with a supporting roof structure primarily made of carbon- and glass-fiber-reinforced composites, fabricated by robotic coreless filament winding. We conducted monitoring to ascertain the sturdiness of the fiber composite material of the supporting structure over the course of 130 days. This paper presents the methods and results of on-site monitoring as well as laboratory inspections. The thermal behavior of the pavilion was characterized, the color change of the matrix was quantified, and the inner composition of the coreless wound structures was investigated. This validated the structural design and revealed that the surface temperatures of the carbon fibers do not exceed the guideline values of flat, black façades and that UV absorbers need to be improved for such applications.