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All aboard! : Elijah McCoy's steam engine
Simple text and illustrations explore the life of inventor, Elijah McCoy. Includes explanation of the saying, \"The real McCoy.\"
Book
The Impact of the Lubricant Dose on the Reduction of Wear Dies Used in the Forging Process of the Valve Forging
The paper presents the results of research on the influence of the settings of lubrication and cooling system parameters (solenoid valve opening time and lubricant feed pressure in terms of its quantity) in order to select the optimal lubricating conditions and thus reduce the wear of the dies used in the first forging operation of the valve forging made of high-nickel steel. Based on the observation of lubrication in the industrial process, it was found that a significant part of the lubricant fails to reach the die cavity, reaching the outside of it, which causes die wear due to seizure resulting from adhesion of the forging material to the tool surface as well as high lubricant consumption and dirt in the press chamber. The authors proposed their own mobile lubricating and cooling system, which allows for a wide range of adjustments and provided with automatic cleaning procedures of the entire system, unlike the fixed lubrication system used so far in the industrial process. First, tests were carried out in laboratory conditions to determine the highest wettability and the lubricant remaining inside the tool cavity. These tests determined the lubrication system parameter settings that ensured that the greatest amount of lubricant remains in the cold die cavity without the forging process. Then, to verify the obtained results, tests were carried out in the industrial process of hot die forging of valve forgings for short production runs of up to 500 forgings. The results were compared with the measurement of changes in the geometry of tools and forgings based on 3D scanning and surface topography analysis with the use of SEM (Scanning Electron Microscope). For the best results (the variant of the setting of the dose and the time of exposure to lubricant), the forging process was carried out with the use of a new tool up to the maximum service life.
Journal Article
Computational analysis of air bubble-induced frictional drag reduction on ship hulls
About 60% of marine vessels’ power is consumed to overcome friction resistance between the hull and water. Air lubrication can effectively reduce this resistance and lower fuel consumption, and consequently emissions. This study aims to analyze the use of a gas-injected liquid lubrication system (GILLS) to reduce friction resistance in a real-world scenario. A 3D computational fluid dynamics model is adopted to analyse how a full-scale ship (the Sea Transport Solutions Designed Catamaran ROPAX ferry) with a length of 44.9 m and a width of 16.5 m is affected by its speed and draught. The computational model is based on a volume of fluid model using the k-ꞷ shear stress transport turbulence model. Results show that at a 1.5 m draught and 20 knots cruising speed, injecting 0.05 kg/s of compressed air into each GILLS unit reduces friction resistance by 10.45%. A hybrid model of natural air suction and force-compressed air shows a friction resistance reduction of 10.41%, which is a promising solution with less required external power. The proposed technique offers improved fuel efficiency and can help to meet environmental regulations without engine modifications.
Journal Article
Numerical and Experimental Investigations on Oil Supply Characteristics of a Multi-Passage Lubrication System for a Three-Stage Planetary Transmission in a Tracked Vehicle
The multi-passage lubrication system is adopted to meet the demand of the main heat generation parts (gears and bearings) in the three-stage planetary transmission system of a large tracked vehicle. As rotational speed increases, the flow regime inside the passages with multi-oil outlets becomes highly complex. Under high-speed conditions, the flow rate in Zone 2 decreases sharply, and some oil outlets even drop to zero, representing a 100% reduction amplitude, which results in an unstable oil supply for heat generation parts and even potential lubrication cut-off. In the present work, the lubrication characteristics of the oil supply system for the three-stage planetary transmission system are investigated by a combination of CFD (computational fluid dynamics) simulations and experiments. A complete CFD model of the multi-passage lubrication system is established, comprising a stationary oil passage, a main oil passage, and a three-stage variable-speed oil passage. A transient calculation method based on sliding mesh rotation domain control is used to simulate the oil-filling process in the oil passages, and the oil supply characteristics of the variable-speed oil passage are investigated. A test bench for the multi-stage planetary transmission system is designed and constructed to collect oil flow data from outlets of planetary gear sets. The comparison between simulated and experimental results confirms the validity of the proposed numerical method. Additionally, numerical simulations are conducted to investigate the effects of key factors, including input speed, oil supply pressure, and oil temperature, on the oil flow rate of outlets. The results indicate that the rotational speed is the major parameter affecting the oil flow rate at the oil passage outlets. This work provides a practical guidance for optimizing lubrication design in complex multi-stage planetary transmission systems.
Journal Article
Numerical Simulation of Startup Performance in High-Power Diesel Engine Lubrication Systems Under High-Altitude and Cold Conditions
With the significant increase in the number of motor vehicles in plateau regions, the adaptability and reliability requirements of diesel engines operating under high-altitude and cold conditions have become increasingly critical. In this study, a one-dimensional transient simulation model of the overall engine lubrication system was developed based on a physical experimental prototype. The multiphysics-coupled lubrication system was numerically modeled and analyzed, with particular emphasis on elucidating the influence mechanisms of high-altitude and cold environments on the startup performance of diesel engine lubrication systems. System responses under different ambient pressures (0.88 bar, 0.92 bar, 0.96 bar, and standard atmospheric pressure) and oil temperatures (30 °C, 55 °C, and 100 °C) were systematically investigated. In addition, variations in the opening degree of the oil pump pressure relief valve (closed, 4%, 30%, 60%, and 100%) were incorporated to reveal the governing effects of high-altitude and cold environments on lubrication system startup behavior. The results indicate that under high-altitude and cold conditions, the decrease in oil temperature is the dominant factor and exerts the most significant influence on the steady-state oil pressure and flow rate of the lubrication system. Variations in ambient pressure lead only to an equivalent shift in absolute oil pressure, with negligible effects on relative oil pressure, steady-state flow rate, response time, or filling rate. However, a reduction in atmospheric pressure leads to a decrease in the peak oil flow rate at the outlet of the oil pump. The opening degree of the pressure relief valve exhibits a nonlinear influence on the startup performance of the lubrication system, and significantly decreases the oil filling rate. This study innovatively develops a lubrication system performance prediction model under high-altitude, low-pressure, and low-temperature conditions. Calibrated using vehicle road-test data, the model quantifies for the first time the relative contributions of the three key factors to start-up lubrication performance, thereby providing a clear decision-making framework and prioritized improvement directions for the reliability-oriented design and safety threshold calibration of lubrication systems in high-altitude diesel engines.
Journal Article
Green-Emitting Carbon Quantum Dots: Highly Sensitive Temperature Sensing Probe in Nanocomposite and Lubrication System
Carbon quantum dots (CQDs) have already demonstrated their utility as lubricant additives, and non-contact temperature sensing based on CQDs offers considerable potential for condition monitoring in mechanical, electrical, and other fields, as well as lubrication-temperature multifunctional applications in lubricants. In this paper, we have successfully synthesized and designed high-brightness carbon quantum dots/polyvinyl alcohol (PVA) temperature sensor thin film and dispersions of CQDs in a liquid paraffin lubrication system. Based on fluorescence intensity and the fluorescence intensity ratio, the carbon quantum dot/PVA film exhibited exponential temperature-dependent properties with a wide applicability range, a high goodness of fit (R2 > 0.99), and high relative thermal sensitivity (relative sensitivities of 1.74% K−1 and 1.39% K−1 for fluorescence intensity and fluorescence intensity ratio, respectively). In addition, based on the fluorescence intensity, the CQDs exhibited a wide temperature range (20–90 °C), a high goodness of fit (R2 > 0.99), and higher sensitivity (2.84% K−1) in a liquid paraffin lubrication system, which reflects the temperature responsive properties of carbon quantum dots as additives in lubrication systems. These findings provide convenient and effective possibilities for the sensing and monitoring of carbon quantum dots and their multifunctional applications under lubrication systems.
Journal Article
Current carrying tribological properties of multi arc ion plated titanium nitride doped silver coating
Sliding electrical contact materials play a crucial role in the transmission and conversion of electrical energy, but due to various factors such as force, electricity, and heat, the interface exhibits complex wear behavior. A single solid or liquid lubrication system can no longer meet the growing performance requirements of current carrying tribology. In this study, a TiN-Ag coating was prepared using multi arc ion plating technology, and a solid–liquid composite lubrication system was formed with ionic liquid and polyurea grease, respectively. Through current carrying friction and wear tests, their tribological properties, electrical contact resistance(ECR) values, and stability were tested, and compared with the results obtained during dry friction. The coating and worn surfaces were analyzed using scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS). The results indicated that compared with dry friction, TiN-Ag coatings lubricated with ionic liquids and polyurea grease showed higher friction reduction, wear resistance, and conductivity, especially the synergistic effect between ionic liquids and coatings is prominent. The behavior of ionic liquids under voltage was analyzed, and it was found that ionic liquids formed a physical adsorption film composed of a mixture of anions and cations on the worn surface. The ordered layered structure improved the tribological performance of the system.
Journal Article
Resilient Optimal Dispatch of Ship-Integrated Energy System and Air Lubrication Using an Enhanced Traffic Jam Optimizer
With increasingly stringent greenhouse gas emission regulations in the shipping industry, there is an urgent need for an efficient energy management strategy for new energy ship power systems. However, existing dispatch models often overlook the dynamic energy-saving potential of active drag reduction technologies and lack effective optimization algorithms capable of handling high-dimensional, multi-constrained problems. To address these problems, this paper proposes a novel integrated dispatch framework for hybrid energy ship power systems that incorporates air lubrication systems. First, a unified multi-energy dispatch model is established, coupling the dynamic operation of air lubrication systems with electrical, thermal, and propulsion energy flows. Second, an Improved Traffic Jam Optimizer algorithm is proposed, which enhances global exploration and local exploitation through a nonlinear parameter adaptation mechanism, differential mutation strategy, and dynamic hybrid search architecture. Convergence analysis based on Markov chain theory is provided to guarantee algorithmic reliability. Simulation results demonstrate that the proposed algorithm outperforms existing methods in terms of convergence speed, solution accuracy, and stability. Furthermore, integrating air lubrication systems into the ship power system reduces total operating costs and greenhouse gas emissions by up to 20.569% and 6.310%, respectively.
Journal Article
Computational Analysis of Air Lubrication System for Commercial Shipping and Impacts on Fuel Consumption
Our study presents the computational implementation of an air lubrication system on a commercial ship with 154,800 m3 Liquified Natural Gas capacity. The air lubrication reduces the skin friction between the ship’s wetted area and sea water. We analyze the real operating conditions as well as the assumptions, that will approach the problem as accurately as possible. The computational analysis is performed with the ANSYS FLUENT software. Two separate geometries (two different models) are drawn for a ship’s hull: with and without an air lubrication system. Our aim is to extract two different skin friction coefficients, which affect the fuel consumption and the CO2 emissions of the ship. A ship’s hull has never been designed before in real scale with air lubrication injectors adjusted in a computational environment, in order to simulate the function of air lubrication system. The system’s impact on the minimization of LNG transfer cost and on the reduction in fuel consumption and CO2 emissions is also examined. The study demonstrates the way to install the entire system in a new building. Fuel consumption can be reduced by up to 8%, and daily savings could reach up to EUR 8000 per travelling day.
Journal Article
Influence of CFD Modelling Parameters on Air Injection Behaviour in Ship Air Lubrication Systems
In response to the International Maritime Organization’s strengthened regulations on carbon emissions, the introduction of novel eco-friendly technologies for ship operators has become necessary. In this context, various energy saving devices such as wind-assisted propulsion systems (e.g., wing/rotor sails), propeller-rudder efficiency enhancers (e.g., pre-swirl stators or ducted propellers), and the gate rudder system have been proposed. Among various energy-saving technologies, the air lubrication system has been widely investigated as an effective means of reducing hull frictional resistance through air injection beneath the hull. The performance of air lubrication systems can be evaluated through experimental testing or computational fluid dynamics (CFD) simulations. However, accurately simulating air lubrication systems in CFD remains challenging. Therefore, this study aims to quantitatively evaluate the influence of numerical parameters on the CFD implementation of air lubrication systems. To evaluate these influences, CFD simulations employing the unsteady Reynolds-averaged Navier–Stokes (URANS) method were conducted to investigate air layer formation and sweep angle on a flat plate. The numerical predictions were systematically compared with experimental results by varying key numerical parameters. These quantitative estimations of the effects of numerical variables are expected to serve as a useful benchmark for CFD simulations of air lubrication systems.
Journal Article