International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 11 Issue: 07 | July 2024
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p-ISSN: 2395-0072
Experimental and CFD Analysis Based Design of Additively Manufactured Drum Gate for Open Channel Flow Experiments Dr. Fayyaz Rehman1, Robert Benham2 1Associate Professor, Department of Science and Engineering, Solent University, Southampton, UK 2Senior Lecturer, Department of Science and Engineering, Solent University, Southampton, UK
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Abstract – Additive Manufacturing (AM) is emerging as a
manufactured parts meet quality standards. AM printed parts providing distinct advantages over conventionally machined components, including reduced production time, lower costs, and the ability to achieve complex geometries. Historically, improvements in weir designs have required extensive empirical testing.
cost-effective alternative to conventional manufacturing techniques for applications requiring components with complex geometries. Cost savings are achieved through reduced raw material usage, shorter manufacturing times, and the elimination of expensive tooling. AM serves as a valuable tool for designing and developing complex shapes in fluid flow research. This study examines the limitations of existing components in a 2.5 m open channel fluid flow experiment, characterized by their basic standard shapes. Specifically, it focuses on enhancing flow control in hydraulic systems by introducing gates with intricate geometries, which are typically expensive and timeconsuming to acquire from equipment suppliers. AM technology provides a cost-effective solution for implementing progressive design modifications. This paper presents a comparative analysis of various positions of an AM-produced curved drum gate in terms of flow rate, fluid velocity profile, water level height, and related fluid flow parameters. Computational Fluid Dynamics (CFD) modelling, analysis, and simulation techniques are used to analyse and validate the results. Based on the experimental findings and their verification, this paper discusses the suitability and applicability of AM techniques in fluid flow analysis. The ability to manufacture customized components through AM offers a promising avenue for enhancing fluid flow research, enabling cost-effective and time-efficient design modifications. This study emphasizes the importance of utilizing AM and specific materials to advance fluid flow analysis.
Additive Manufacturing (AM) has emerged as a promising technology for conducting fluid mechanics experiments, offering numerous possibilities. Gated spillways have attracted significant interest due to their control capabilities and reduced footprint. However, crest gates face challenges such as gate failure, support member buckling, and friction-related issues. Alternatively, radial or Tainter gates have been historically used, though they present downstream complications from high-velocity movement, cavitation probability, and aeration. Mousavimehr et al. [1] investigated shockwave effects and proposed experimental methods to mitigate them, recognizing AM's potential in fluid flow research. Musa et al. [2] reviewed AM's established role in experimental fluid flow research, highlighting its significance and potential advancements in various areas. The existing experiment at the university for undergraduate Mechanical Engineering students uses a 2.5 m long flow channel (Figure 1), enabling various experiments to observe open channel flow behaviour with different components. This experiment currently involves only a standard round aluminium-based drum gate component. However, this standard round configuration is insufficient to fully understand the complexities of practical drum gate use with different shapes.
Key Words: CFD Analysis, Additive Manufacturing, Experimental Methods
The case study presented in this paper extends previously published research [3] by the authors, providing detailed experimental and computational fluid dynamics (CFD) analysis of the effects of changing the drum gate shape for various open channel experiments using additive manufacturing technology.
1. INTRODUCTION Additive Manufacturing (AM) is a relatively modern and innovative technology for designing and producing polymeric and metallic components, offering advantages over traditional manufacturing methods such as machining, casting, or moulding. AM enables the creation of innovative designs concerning material, shape, and complexity by eliminating the need for tooling. This removes many current design-for-manufacturing and assembly restrictions. However, AM processes have unique characteristics and requirements that must be considered during the design stage to ensure the
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