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latex/Kapitel/simulation.tex
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@ -7,8 +7,6 @@ see appendix~\ref{apx:pub4}
\chapter{Rotating 3D Crankshaft}
\section{Geometry}
A \acrshort{cad} model of a forged 6 cylinder diesel crankshaft was provided by the manufacturer.
@ -23,19 +21,18 @@ The geometry was then cut at the first and second main bearings so reduce the si
\end{figure}
% \begin{figure}[htbp]
% \centering
% \includegraphics[width=0.5\linewidth]{example-image}
% \caption{CAD model of the inductor.}\label{fig:cad-inductor}
% \end{figure}
A \acrshort{cad} model of the inductor was created from a technical drawing and incorporated into the global mesh.
\begin{figure}[htbp]
\centering
\includegraphics[width=0.5\linewidth]{example-image}
\caption{CAD model of the inductor.}\label{fig:cad-inductor}
\end{figure}
Its geometry was simplified by cutting the plumbing leading up to the horse shoe induction coil and replacing it with straight radial tubing.
The mesh was generated by our partners at the \acrshort{ecs}, with the following key properties:
The bearing's surface element size was ??, growing fo a coarser ?? after 5 mm depth, with the webbing and rest od the crankshaft set to an element size of ??.
The inductor was sized to ?? at the field-generating portion and above that was replaced with radial struts meshed to ??.
The air was set to ?? in the gap between the bearing and the inductor, growing to ?? at the model boundary.
The bearing's surface element size was \qty{0}{\mm}??, growing fo a coarser \qty{0}{\mm}?? after 5 mm depth, with the webbing and rest od the crankshaft set to an element size of \qty{0}{\mm}??.
The inductor was sized to \qty{0}{\mm}?? at the field-generating portion and above that was replaced with radial struts meshed to \qty{0}{\mm}??.
The air was set to \qty{0}{\mm}?? in the gap between the bearing and the inductor, growing to \qty{0}{\mm}?? at the model boundary.
Figure~\ref{fig:crank-sim-inductor-net} shows the bulk of these portions in a cutaway, with the inductor and bearing surface shown in red to highlight their grouping for rotation.
\begin{figure}[htbp]
@ -186,12 +183,12 @@ The calculation of a single electromagnetic iteration step on the \acrshort{mcl}
The process is made up of \num{5.5} revolutions of the crankshaft at a coarse increment of \ang{10} per time step, which sum up to \num{195} individual thermal simulations.
The average amount of iteration steps required until the Labridis algorithm converges was observed to lie at \num{\sim 15}.
Thus the estimated time to completion for just the electromagnetic portion of the rotational model amounts to 438 days!
Thus the estimated time to completion for just the electromagnetic portion of the rotational model amounts to 438 days.
A majority of this time is spent on overhead due to repeated restarts of the \emph{Abaqus} solver, and the electromagnetic itself is made inefficient due to the solver not making use of more than a single processing core.
(For larger models the bulk of said overhead is spent on pre-processing, for smaller models the loading of the \emph{Abaqus CAE} software and license acquisition dominate proportionately.)
(For larger models the bulk of said overhead is spent on pre-processing; for smaller models the loading of the \emph{Abaqus CAE} software and license acquisition dominate proportionately.)
{\color{red}Based on the general lack of support for electromagnetic calculations (absent EM user subroutines, single core solving), \emph{Abaqus CAE} is not suitable for large induction models!}
{\color{red}Based on the general lack of support for electromagnetic calculations (absent EM user subroutines, single core solving), \emph{Abaqus CAE} is not suitable for large induction models!??}
\section{Alternative Calculation Scheme}
@ -231,31 +228,31 @@ The results obtained by the thermal approximation were
\subfloat[Axial Stresses after heating]{\includegraphics[width = 0.45\linewidth]{Abbildungen/kw-th-heating-S-Axi.png}} &
\subfloat[Axial Stresses after quenching]{\includegraphics[width = 0.45\linewidth]{Abbildungen/kw-th-aircool-S-Axi.png}}
\end{tabular}
\caption[Stress component distribuiton of crankshaft.]{Sectional views of stress component distributions before and after quenching. It must be noted that the image scales of \textbf{(a)}, \textbf{(c)},and \textbf{(e)} are equalized but reduced by a factor 3 to those of \textbf{(b)}, \textbf{(d)}, and \textbf{(f)}.}\label{fig:enter-label}
\caption[Stress component distribuiton of crankshaft.]{Sectional views of stress component distributions before and after quenching. It must be noted that the image scales of \textbf{(a)}, \textbf{(c)},and \textbf{(e)} are equalized but reduced by a factor 3 to those of \textbf{(b)}, \textbf{(d)}, and \textbf{(f)}.}\label{fig:plate-stress-distro}
\end{figure}
\begin{figure}[htbp]
\centering
\includegraphics[width=\linewidth]{Abbildungen/kw_th_time_data_heat_axi.png}
\caption{Evolution of axial strain components and stresses during heating.}\label{fig:time_data}
\caption{Evolution of axial strain components and stresses during heating.}\label{fig:time_data_ax_h}
\end{figure}
\begin{figure}[htbp]
\centering
\includegraphics[width=\linewidth]{Abbildungen/kw_th_time_data_heat_tan.png}
\caption{Evolution of tangential strain components and stresses during heating.}\label{fig:enter-label}
\caption{Evolution of tangential strain components and stresses during heating.}\label{fig:time_data_tan_h}
\end{figure}
\begin{figure}[htbp]
\centering
\includegraphics[width=\linewidth]{Abbildungen/kw_th_time_data_quench_axi.png}
\caption{Evolution of axial strain components and stresses during quenching.}\label{fig:time_data}
\caption{Evolution of axial strain components and stresses during quenching.}\label{fig:time_data_ax_q}
\end{figure}
\begin{figure}[htbp]
\centering
\includegraphics[width=\linewidth]{Abbildungen/kw_th_time_data_quench_tan.png}
\caption{Evolution of tangential strain components and stresses during quenching.}\label{fig:enter-label}
\caption{Evolution of tangential strain components and stresses during quenching.}\label{fig:time_data_tan_q}
\end{figure}
@ -269,7 +266,7 @@ The results obtained by the thermal approximation were
\subfloat[full Mechanical Mesh]{\includegraphics[width=0.4\linewidth]{Abbildungen/KW_mech_full.png}} \quad\quad
\subfloat[Free-cut Sample plate Mesh]{\includegraphics[width=0.4\linewidth]{Abbildungen/KW_mech_cut.png}}
\caption{Meshes of the two steps during the free-cutting simulation.}\label{fig:hexrd-smple-cut-sim}
\caption{Meshes of the two steps during the free-cutting simulation.}\label{fig:hexrd-sample-cut-sim}
\end{figure}
@ -277,21 +274,21 @@ The results obtained by the thermal approximation were
\begin{figure}[thbp]
\centering
\includegraphics[width=0.75\linewidth]{Abbildungen/kw-th-cut-S-Rad_vgl.png}
\caption[Comparison of radial stresses before and after cutting plates.]{Comparison of radial stresses before \textbf{(left)} and after \textbf{(right)} cutting the sample plate.}\label{fig:enter-label}
\caption[Comparison of radial stresses before and after cutting plates.]{Comparison of radial stresses before \textbf{(left)} and after \textbf{(right)} cutting the sample plate.}\label{fig:plate_cut_stress_rad}
\end{figure}
\begin{figure}[thbp]
\centering
\includegraphics[width=0.75\linewidth]{Abbildungen/kw-th-cut-S-Tan_vgl.png}
\caption[Comparison of tangential stresses before and after cutting plates.]{Comparison of tangential stresses before \textbf{(left)} and after \textbf{(right)} cutting the sample plate.}\label{fig:enter-label}
\caption[Comparison of tangential stresses before and after cutting plates.]{Comparison of tangential stresses before \textbf{(left)} and after \textbf{(right)} cutting the sample plate.}\label{fig:plate_cut_stress_tan}
\end{figure}
\begin{figure}[thbp]
\centering
\includegraphics[width=0.75\linewidth]{Abbildungen/kw-th-cut-S-Axi_vgl.png}
\caption[Comparison of axial stresses before and after cutting plates.]{Comparison of axial stresses before \textbf{(left)} and after \textbf{(right)} cutting the sample plate.}\label{fig:enter-label}
\caption[Comparison of axial stresses before and after cutting plates.]{Comparison of axial stresses before \textbf{(left)} and after \textbf{(right)} cutting the sample plate.}\label{fig:plate_cut_stress_ax}
\end{figure}
\begin{figure}[thbp]
@ -304,29 +301,29 @@ The results obtained by the thermal approximation were
\subfloat[Disk 1 - Axial]{\includegraphics[width=0.49\linewidth]{Abbildungen/kw-th-disk1-S-Axi-vgl.png}} &
\subfloat[Disk 2 - Axial]{\includegraphics[width=0.49\linewidth]{Abbildungen/kw-th-disk2-S-Axi-vgl.png}} \\
\end{tabular}
\caption[Comparison of stresses before and after cutting disks.]{Comparison of stresses before \textbf{(left)} and after \textbf{(right)} cutting sample disks.}\label{fig:enter-label}
\caption[Comparison of stresses before and after cutting disks.]{Comparison of stresses before \textbf{(left)} and after \textbf{(right)} cutting sample disks.}\label{fig:disk_cut_stress}
\end{figure}
\begin{figure}
\centering
\includegraphics[width=0.6\linewidth]{Abbildungen/kw_th_vgl_rad.png}
\caption[Comparison of radial stresses between HEXRD and simulation.]{Comparison of radial stresses measured by HEXRD \textbf{(left)} and calculated by \textit{Abaqus} \textbf{(right)}. }\label{fig:enter-label}
\caption[Comparison of radial stresses between HEXRD and simulation.]{Comparison of radial stresses measured by HEXRD \textbf{(left)} and calculated by \textit{Abaqus} \textbf{(right)}. }\label{fig:plate_stress_comp_rad}
\end{figure}
\begin{figure}
\centering
\includegraphics[width=0.6\linewidth]{Abbildungen/kw_th_vgl_axi.png}
\caption[Comparison of axial stresses between HEXRD and simulation.]{Comparison of axial stresses measured by HEXRD \textbf{(left)} and calculated by \textit{Abaqus} \textbf{(right)}. }\label{fig:enter-label}
\caption[Comparison of axial stresses between HEXRD and simulation.]{Comparison of axial stresses measured by HEXRD \textbf{(left)} and calculated by \textit{Abaqus} \textbf{(right)}. }\label{fig:plate_stress_comp_ax}
\end{figure}
\begin{figure}
\centering
\includegraphics[width=0.6\linewidth]{Abbildungen/kw_th_vgl_tau.png}
\caption[Comparison of shear stresses between HEXRD and simulation.]{Comparison of shear stresses measured by HEXRD \textbf{(left)} and calculated by \textit{Abaqus} \textbf{(right)}. }\label{fig:enter-label}
\caption[Comparison of shear stresses between HEXRD and simulation.]{Comparison of shear stresses measured by HEXRD \textbf{(left)} and calculated by \textit{Abaqus} \textbf{(right)}. }\label{fig:plate_stress_comp_tau}
\end{figure}
\begin{figure}
\centering
\includegraphics[width=0.6\linewidth]{Abbildungen/kw_th_vgl_delta-s.png}
\caption[Comparison of differential stresses between HEXRD and simulation.]{Comparison of the differential stress $\sigma_{axi} - \sigma_{rad}$ along line \textbf{V} as measured by HEXRD \textbf{(red)} and calculated by \textit{Abaqus} \textbf{(blue)}. }\label{fig:enter-label}
\caption[Comparison of differential stresses between HEXRD and simulation.]{Comparison of the differential stress $\sigma_{axi} - \sigma_{rad}$ along line \textbf{V} as measured by HEXRD \textbf{(red)} and calculated by \textit{Abaqus} \textbf{(blue)}. }\label{fig:plate_stress_comp_delta}
\end{figure}

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latex/todo.md
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@ -1,4 +1,5 @@
# ToDos Dissertation
## writing (NOW!!)
- [] Introduction
- [] State of the Art
@ -16,9 +17,18 @@
- [] Results
- [] Crankshaft
- [] Validation
- [] Results Description
- [] Validation
- [] Results
- [] Discussion
- [] Conclusion
## editing (LATER!!)
- [] Figures
- [X] Short captions for Index
- [] Unify Captions
- [] Style
- [] Cpatialize references or no?
- [] chack all dashes ?