Special Issue of the Manufacturing Engineering Society 2021 (SIMES-2021).

After the complete success of the first [...].

A strict formulation of a nonlinear Helmholtz equation for the propagation of sound in bubbly liquids. Part II: Application to ultrasonic cavitation.

This paper addresses one of the greatest challenges in sonochemistry that has impaired scaling up ultrasonic processes, which is the lack of models capable of predicting the pressure distribution in sonoreactors. This work studies the effect of acoustic pressure on the transmission of sound thought cavitating bubbly liquids by utilizing the nonlinear Helmholtz equation that was demonstrated on the paper part I. The model showed that the wave number and the attenuation can be estimated from the bubble dynamics of inertial bubbles and the local bubble density. The linear model of Commander and Prosperetti is encompassed by the nonlinear model. The model was employed to predict the pressure distribution below an ultrasonic horn tip achieving a relatively close prediction of the experimental data and certainly an accurate qualitative description of the distribution of the pressure field in spite of the simplifications of the model and the assumptions of unknown variables such as the bubble density, bubble distribution and the vessel boundary conditions.

A strict formulation of a nonlinear Helmholtz equation for the propagation of sound in bubbly liquids. Part I: Theory and validation at low acoustic pressure amplitudes.

This paper strictly demonstrated a nonlinear Helmholtz equation, with its corresponding new expressions for the wave number of the mixture, for the propagation of sound trough a bubbly liquid. The demonstration was conducted under the assumption of periodicity of volume fluctuations, the acoustic approximation and considering only mono-harmonic pressure oscillations. The model revealed a beautiful symmetry between the average acoustic energy density and the average energy dissipation, as well as between the time average of the first and second derivatives of such fluctuations. The nonlinear model was validated with available experimental data at very low pressure amplitudes yielding the same results as the linear model. However, unlike the linear model, the advantage of the nonlinear model is that the wave number of the mixture is function of the pressure amplitude, which has great implications to model the sound propagation on cavitating bubbly liquids where the linear theory greatly under-predicts.

Experimental Parametric Model for Indirect Adhesion Wear Measurement in the Dry Turning of UNS A97075 (Al-Zn) Alloy.

In this work, the study of the influence of cutting parameters (cutting speed, feed, and depth of cut) on the tool wear used in in the dry turning of cylindrical bars of the UNS A97075 (Al-Zn) alloy, has been analyzed. In addition, a study of the physicochemical mechanisms of the secondary adhesion wear has been carried out. The behavior of this alloy, from the point of view of tool wear, has been compared to similar aeronautical aluminum alloys, such as the UNS A92024 (Al-Cu) alloy and UNS A97050 (Al-Zn) alloy. Furthermore, a first approach to the measurement of the 2D surface of the adhered material on the rake face of the tool has been conducted. Finally, a parametric model has been developed from the experimental results. This model allows predicting the intensity of the secondary adhesion wear as a function of the cutting parameters applied.

Hardening Effect Analysis by Modular Upper Bound and Finite Element Methods in Indentation of Aluminum, Steel, Titanium and Superalloys.

The application of incremental processes in the manufacturing industry is having a great development in recent years. The first stage of an Incremental Forming Process can be defined as an indentation. Because of this, the indentation process is starting to be widely studied, not only as a hardening test but also as a forming process. Thus, in this work, an analysis of the indentation process under the new Modular Upper Bound perspective has been performed. The modular implementation has several advantages, including the possibility of the introduction of different parameters to extend the study, such as the friction effect, the temperature or the hardening effect studied in this paper. The main objective of the present work is to analyze the three hardening models developed depending on the material characteristics. In order to support the validation of the hardening models, finite element analyses of diverse materials under an indentation are carried out. Results obtained from the Modular Upper Bound are in concordance with the results obtained from the numerical analyses. In addition, the numerical and analytical methods are in concordance with the results previously obtained in the experimental indentation of annealed aluminum A92030. Due to the introduction of the hardening factor, the new modular distribution is a suitable option for the analysis of indentation process.

A computational modeling approach of the jet-like acoustic streaming and heat generation induced by low frequency high power ultrasonic horn reactors.

High power ultrasound reactors have gained a lot of interest in the food industry given the effects that can arise from ultrasonic-induced cavitation in liquid foods. However, most of the new food processing developments have been based on empirical approaches. Thus, there is a need for mathematical models which help to understand, optimize, and scale up ultrasonic reactors. In this work, a computational fluid dynamics (CFD) model was developed to predict the acoustic streaming and induced heat generated by an ultrasonic horn reactor. In the model it is assumed that the horn tip is a fluid inlet, where a turbulent jet flow is injected into the vessel. The hydrodynamic momentum rate of the incoming jet is assumed to be equal to the total acoustic momentum rate emitted by the acoustic power source. CFD velocity predictions show excellent agreement with the experimental data for power densities higher than W(0)/V ≥ 25kWm(-3). This model successfully describes hydrodynamic fields (streaming) generated by low-frequency-high-power ultrasound.