Journal of Engineering Science, Volume 4, Issue 2 (2017) by Journal of Engineering Sciences

SUMY STATE UNIVERSITY

p-ISSN 2312-2498 e-ISSN 2414-9381 http://jes.sumdu.edu.ua

JOURNAL OF ENGINEERING SCIENCES УРНА ІН Н РНИХ НАУ УРНА ИН Н РНЫХ НАУ Volume 4 Issue 2 (2017)

The Ministry of Education and Science of Ukraine У я

JOURNAL OF ENGINEERING SCIENCES

РНА ІН

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Scientific Journal

Volume 4, Issue 2 (2017) ом 4, № 2 (2017)

Founded in 1994 З

1994 1994

Sumy State University С С

The Journal of Engineering Sciences is an open access scientific journal that covers urgent issues of the modern high-tech production, development of new scientific engineering trends and future technologies. p-ISSN 2312-2498 e-ISSN 2414-9381

Recommended for publication by the Academic Council of Sumy State University, (minutes No. 4 of 14.12.2017)

The Journal is the scientific professional edition of Ukraine in the field of Engineering Sciences (ordered by the Ministry of Education and Science of Ukraine, July 13, 2015, No. 747): http://old.mon.gov.ua/img/zstored/files/747.rar).

The Journal of Engineering Sciences is published with the support of: – the Faculty of Technical Systems and Energy Efficient Technologies of Sumy State University (Sumy, Ukraine): http://teset.sumdu.edu.ua; – the Faculty of Manufacturing Technologies with a seat in Prešov of Technical University of Košice (Prešov, Slovak Republic): http://fvt.tuke.sk; – the Department of General Chemistry of Sumy State University (Sumy, Ukraine): http://chem.teset.sumdu.edu.ua.

Editorial Board: Contact Phones: E-mail: Web-site:

2 Rymskogo-Korsakova St., 40007, Sumy, Ukraine +38 (0542) 334 109; +38 (0542) 687 852 jes.sumdu@gmail.com http://jes.sumdu.edu.ua

State registration certificate of the print mass-media No. 2312-2498. Sumy State University, 2017

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Journal of Engineering Sciences, Volume 4, Issue 2 (2017), pp. iii–v

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ЕDITORIAL BOARD EDITOR-IN-CHIEF Kryvoruchko D. V., Doctor of Sciences, Professor, Sumy State University, Sumy, Ukraine.

MANAGING EDITOR Pavlenko I. V., Ph.D., Associate Professor, International Engineer-Educator ING. PAED. IGIP, Sumy State University, Sumy, Ukraine.

ADVISORY EDITOR Martsynkovskyy V. A., Doctor of Sciences, Professor, Sumy State University, Sumy, Ukraine.

DUPUTY CHIEF EDITORS Zaloga V. O., Doctor of Sciences, Professor, Sumy State University, Sumy, Ukraine; Sklabinskiy V. I., Doctor of Sciences, Professor, Sumy State University, Sumy, Ukraine; Gusak O. G., Ph.D., Associate Professor, Sumy State University, Sumy, Ukraine.

TECHNICAL SECRETARY Berladir K. V., Ph.D., Assistant Professor, Sumy State University, Sumy, Ukraine.

MEMBERS OF THE EDITORIAL BOARD Rong Y. (K.), Doctor of Sciences, Professor, Worcester Polytechnic University, Worcester, USA; South University of Science and Technology, Shenzhen, China; Zajac J., Doctor of Sciences, Professor, Technical University of Kosice, Presov, Slovakia; Pitel J., Doctor of Sciences, Professor, Technical University of Kosice, Presov, Slovakia; Hatala M., Ph.D., Associate Professor, Technical University of Kosice, Presov, Slovakia; Petrus R., Doctor of Sciences, Professor, Politechnika Rzeszowska, Rzeszow, Poland; Kundera Cz., Doctor of Sciences, Professor, Kielce University of Technology, Kielce, Poland; Storchak M. G., Doctor of Sciences, Professor, Institute for Machine Tools of Stuttgart University, Stuttgart, Germany; Klimenko S. A., Doctor of Sciences, Professor, Bakul Institute for Superhard Materials of the National Academy of Sciences of Ukraine, Kyiv, Ukraine; Lvov G. I., Doctor of Sciences, Professor, National Technical University “Kharkiv Polytechnic Institute”, Kharkiv, Ukraine; Vereshchaka A. S., Doctor of Sciences, Professor, Moscow State Technical University “Stankin”, Moscow, Russian Federation; Shvets S. V., Ph.D., Associate Professor, Sumy State University, Sumy, Ukraine; Kolesnikov V. I., Doctor of Sciences, Professor, Rostov State Transport University, Rostov-on-Don, Russian Federation; Pavlenko V. I., Doctor of Sciences, Professor, Belgorod State Technological University, Belgorod, Russian Federation; Matsevityi Yu. M., Doctor of Sciences, Professor, A. Podgornyi Institute for Problems of Mechanical Engineering of National Academy of Sciences of Ukraine, Kharkiv, Ukraine; Fedorovich V. A. , Doctor of Sciences, Professor, National Technical University “Kharkiv Polytechnic Institute”, Kharkiv, Ukraine; Filimonikhin G. B. ,Doctor of Sciences, Professor, Kirovograd National Technical University, Kropyvnytskyi, Ukraine; Pochyly F., Doctor of Sciences, Professor, Brno Technical University, Brno, Czech Republic; Kamburg V. G., Doctor of Sciences, Professor, Penza State University of Architecture and Building, Penza, Russian Federation;

Editorial Board

Atamanyuk V. M., Doctor of Sciences, Professor, Lviv Polytechnic National University, Lviv, Ukraine; Vereshchaka S. M., Doctor of Sciences, Professor, Sumy State University, Sumy, Ukraine; Dyadyura K. O., Doctor of Sciences, Professor, Sumy State University, Sumy, Ukraine; Karpus V. E., Doctor of Sciences, Professor, Academy of Internal Forces of the Ministry of Internal Affairs, Kharkiv, Ukraine; Plyatsuk L. D., Doctor of Sciences, Professor, Sumy State University, Sumy, Ukraine; Varchola M., Doctor of Sciences, Professor, Slovak University of Technology in Bratislava, Slovakia; Karintsev I. B., Ph.D., Professor, Sumy State University, Sumy, Ukraine; Kovalyov I. O., Ph.D., Professor, Sumy State University, Sumy, Ukraine; Mazur M. P., Doctor of Sciences, Professor, Khmelnytskyi National University, Khmelnytskyi, Ukraine; Petrakov Yu. V., Doctor of Sciences, Professor, National Technical University of Ukraine “I. Sikorsky Kyiv Polytechnic Institute”, Kyiv, Ukraine; Symonovskyy V. I., Doctor of Sciences, Professor, Sumy State University, Sumy, Ukraine; Sirenko G. O., Doctor of Sciences, Professor, Vasyl Stefanyk Precarpathian National University, Ivano-Frankivsk, Ukraine; Shaporev V. P., Doctor of Sciences, Professor, National Technical University “Kharkiv Polytechnic Institute”, Kharkiv, Ukraine; Ivchenko O. V., Ph.D., Associate Professor, Sumy State University, Sumy, Ukraine.

The Editorial Board of the Journal of Engineering Sciences accepts the articles within the following topics: A. Manufacturing Engineering, Machines and Tools. B. Investigation of Operating Processes in Machines and Devices. C. D. E. F.

Dynamics and Strength. Hermomechanics. Technical Regulation and Metrological Support. Advanced Energy Efficient Technologies. Materials Science.

G. Environmental Engineering. H. Computational Engineering.

Journal of Engineering Sciences, Volume 4, Issue 2 (2017), pp. iii–v

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Web site: http://jes.sumdu.edu.ua Volume 4, Issue 2 (2017)

CONTENTS INVESTIGATION OF OPERATING PROCESSES IN MACHINES AND DEVICES

Moiseev V., anoilo E., Hrubnik A., Vasyliev M., Davydov D. Cleaning and disposal of gas emissions from the production of calcinated soda ash DOI: 10.21272/jes.2017.4(2).b1

B 1–B 6

Skidin I. E., Kalinin V. T., Tkach V. V., Saitkhareiev L. N., Zhbanova O. M. Alternative technology to manufacture bimetallic products by using self-propagating high temperature synthesis DOI: 10.21272/jes.2017.4(2).b7 Qazi H. A. A. Study of verification and validation of standard welding procedure specifications guidelines for API 5L X-70 grade line pipe welding DOI: 10.21272/jes.2017.4(2).b11 Lebedev V. A., Novykov S. V. The hypothesis of formation of the structure of surfaced metal at the surfacing based on the application of the prognostic algorithm of control the electrode wire speed DOI: 10.21272/jes.2017.4(2).b15

B 7–B 10

B 11–B 14

B 15–B 18

Pavlenko I. V., Liaposhchenko O. O., Demianenko M. M., Starynskyi O. E. Static calculation of the dynamic deflection elements for separation devices DOI: 10.21272/jes.2017.4(2).b19

B 19–B 24

MATERIALS SCIENCES

Yanovska G. O., Bolshanina S. B., Kuznetsov V. M. Formation of hydroxyapatite coatings with addition of chitosan from aqueous solutions by thermal substrate method DOI: 10.21272/jes.2017.4(2).f1

F 1–F 4

Zhbanova O. M. Influence effect of electric action on the micro structure of steel in crystallization DOI: 10.21272/jes.2017.4(2).f5

F 5–F 7

Hovorun T. P., Berladir K. V., Pererva V. I., Rudenko S. G., Martynov A. I. Modern materials for automotive industry DOI: 10.21272/jes.2017.4(2).f8

F 8-F 18

Contents

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ENVIRONMENTAL ENGINEERING

Plyatsuk L. D., Vaskina I. V., Kozii I. S., Solianyk V. A., Vaskin R. A., Jakhnenko O. M. Modeling of waterborne pollution of roadside soils DOI: 10.21272/jes.2017.4(2).g1

G 1–G 5

Chernysh Ye. Yu., Plyatsuk L. D., Yakhnenko O. M., Trunova I. O. Modelling of the vertical migration process of phosphogypsum components in the soil profile DOI: 10.21272/jes.2017.4(2).g6

G 6–G 11

Hurets L. L., Kozii I. S. , Miakaieva H. M. Directions of the environmental protection processes optimization at heat power engineering enterprises DOI: 10.21272/jes.2017.4(2).g12

G 12–G 16

Plyatsuk L. D., Burla O. A., Ablieieva I. Yu., Hurets L. L., Roy I. O. Investigation of produced waters radioactivity of oil and gas deposits in the Dnieper-Donets province DOI: 10.21272/jes.2017.4(2).g17

G 17–G 21

COMPUTATIONAL ENGINEERING

Zakharchenko V. P., Marchenko А. V., Nenia V. H. Model of the management program for a means complex of the design works automation as a finite-state automaton DOI: 10.21272/jes.2017.4(2).h1 Salaimeh S. A., Hjouj А. A. Visual object-oriented technology and case-tools of developing the Internet / Intranet-oriented training courses DOI: 10.21272/jes.2017.4(2).h9 Podrigalo M. A., Korobko А. I., Dubinin E. A., Tarasov Yu. V., Baytzur M. V. Development of the method for estimating the inertia radius relative to the vertical axis of the car DOI: 10.21272/jes.2017.4(2).h12

H 1–H 8

H 9–H 11

H 12–H 16

Contents

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DOI: 10.21272/jes.2017.4(2).b1

Volume 4, Issue 2 (2017) UDC 66.01.011

Cleaning and disposal of gas emissions from the production of calcinated soda ash Moiseev V., Мanoilo E., Hrubnik A.*, Vasyliev M., Davydov D. National Technical University “Kharkiv Polytechnic Institute”, 2 Kyrpychova St., 61002, Kharkiv, Ukraine Article info: Paper received: The final version of the paper received: Paper accepted online:

Corresponding Author’s Address:

October 30, 2017 November 25, 2017 November 27, 2017

gr_alia@mail.ru

Abstract. The article is devoted to the issues of reducing the negative impact on the environment of the production of soda ash, which is achieved by reducing the formation of gas and dust emissions, as well as their deeper cleaning. The problem of cleaning gas emissions from the production of soda ash is solved by using hollow vortex devices, their comparison with operating apparatus is given. The advantages of multi-stage vortex-type apparatuses for cleaning large volumes of industrial gas emissions are noted. The article states that the task of cleaning of industrial gas emissions is significantly complicated by their large volumes, which makes it difficult to use traditional treatment equipment. Most of the devices currently used to clean gases from gaseous, liquid and solid impurities are characterized by low throughput due to small maximum permissible gas velocities in the apparatus. The necessity of using multistage vortex devices for cleaning gas emissions from ammonia and soda dust is substantiated. The advantages of the apparatus of this group are noted - low hydraulic resistance, high efficiency and low energy and metal capacity. The comparison of vortex devices with other active gas cleaning devices according to fractional efficiency is given. The scheme of purification of gas emissions from soda dust, with its further utilization, is proposed. The efficiency of submicron particle deposition in a vortex apparatus with intensive phase interaction may exceed 95 %. Keywords: industrial gas emissions, cleaning, mass transfer, vortex apparatus, investigation of cleaning processes, ammonia, soda ash dust.

1 Introduction Waste-free and low-waste technologies represent one of the current trends in the development of industrial production and are associated with the need to eliminate the harmful effects of industrial waste on the environment. Wasteless production involves the development of technological processes that ensure the integrated processing of raw materials. This makes it possible to effectively use natural resources, process waste into commercial products, and also reduce the amount of waste and their negative impact on ecological systems. Wasteless and low-waste technologies are used in all industries, developing in the direction of developing and implementing fundamentally new technological processes that reduce the amount of waste; development and introduction of methods and equipment for waste processing into commercial products; creation of drainless water recycling systems in which water purification is carried out and the efficiency of gas phase cleaning is improved.

To reduce the level of environmental pollution, save raw materials and energy, re-use of material resources, namely their recycling, is of great importance. A set of measures to minimize the amount of hazardous waste and reduce their impact on the environment include: ─ development of drainless process systems and water cycle systems based on wastewater treatment; ─ the development of systems for processing waste products into secondary material resources; ─ creation and release of new types of products, taking into consideration the requirements for its re-use; ─ the creation of fundamentally new production processes that make it possible to exclude or reduce the technological stages at which waste is generated. The initial stage of these complex measures aimed at creating in the future non-waste technologies is the introduction of circulating, down to completely closed technological systems. Turnover water supply is a technical system that provides for the reuse of waste water in the production (after

Journal of Engineering Sciences, Volume 4, Issue 2 (2017), pp. B 1–B 6

treatment) with very limited discharge (up to 3 %) into water bodies. A closed cycle of water use is a system of industrial water supply and sanitation, in which the repeated use of water in the same production process is carried out without the discharge of sewage and other water into natural water bodies. Progress of new technological schemes of water supply is determined by the extent to which the water consumption, the amount of sewage and their contamination decreased compared to earlier ones. The presence of a large amount of sewage at an industrial facility is considered an objective indicator of the imperfection of the technological schemes used. The development of non-waste and anhydrous technological processes is the most rational way of protecting the environment from pollution, which allows to significantly reduce anthropogenic load. The complete transfer of industrial and agricultural production to wasteless and waterless technologies is associated with complex organizational, technical and financial problems. The concept of non-waste production provides for the need to include the consumption sphere in the cycle of using raw materials. Thus, products after physical or moral deterioration should be returned to the production sphere, methods of neutralization, utilization, processing or disposal of waste should be improved. It should be noted that non-waste production involves the cooperation of industries with a large amount of waste (the production of phosphate fertilizers, thermal power plants, metallurgical, mining and concentrating industries) with the production-consumer of this waste. By disposing of sulfur dioxide contained in the exhaust gases, heat and power engineering and metallurgy, it is possible to obtain a large amount of sulfuric acid by increasing the production of this valuable product of chemistry. Sulfuric acid, used in agriculture to make neutralizing composition, can find an unlimited market for soils of soda salinity. Technological measures to protect atmospheric air from pollution also involve the creation of waste-free and low-waste technologies and technological means for the integrated use of raw materials, the disposal of industrial waste, the organization of technological industrial complexes with a closed system of material balance of substances, including production waste. The most effective measure of atmospheric air protection is the construction of enterprises operating on the principle of non-waste technologies, with closed technological processes, with the elimination of emissions of tailings and tail gases into the atmosphere. The introduction of even partial recirculation of gases, replacement of coal and fuel oil with natural gas give a good ecological and economic effect. The change in technology follows the path of reducing the amount of emissions and reducing the costs of gas cleaning per unit of output.

One of the promising directions for the development of wasteless and low-waste technologies is the introduction of gas cleaning with the use of a catalytic afterburning system, which is used for cleaning solvent vapors of paints containing organic and non-oxidized substances: esters, hydrocarbons, toluene, xylene. Considerable practical importance for gas purification is also provided by preventive measures, consisting in improving fuel combustion conditions, improving the design of filters and other gas, dust-collecting equipment, and sealing technological lines. The main criteria of technologies for waste processing are environmental safety and economic efficiency, expressed in the cost of processing one ton of waste. Technologies for recycling production wastes can be classified as follows [1]: ─ thermal technologies; ─ physicochemical technologies; ─ biotechnology. The development of waste-free and water-free processes - the most efficient way to protect the environment from pollution, which drastically reduce the human pressure on the environment. Effectively solve the problems of environmental protection and rational use of natural resources is possible only by improving the methods of neutralization, utilization, processing or disposal of waste.

2 Analysis of recent research The chemical industry complex lays the foundation for long-term and stable development of the country and has a significant impact on structural changes in the economy. The branch of chemistry and petrochemistry is characterized by a wide range of types of products that are used in virtually all industries, the national economy and in everyday life. Analysis of the structure of consumption of soda ash showed that about 49 % of soda ash is used for the production of glass, about a quarter for chemicals, 13 % for soap and detergents, 11 % for purposes such as cellulose and paper, refining metals and oil, tanning skin and water purification, and the rest goes on sale. On Fig. 1 the structure of consumption of soda ash in Ukraine is presented. Other 12%

Paper industry 3%

Oil and petrochemicals 23%

Metallurgy 13% Glass production 49%

Figure 1 – The structure of consumption of soda ash in Ukraine

Investigation of Operating Processes in Machines and Devices

The growth in industrial production caused an increase in emissions to the environment, and the development of a large number of new technological processes led to an increase in the number of toxic substances entering the atmosphere. The total amount of harmful substances in emissions is small, but due to the location of soda plants in regions with chemical plants and the proximity of residential areas, concentrations in the residential area and at the boundaries of sanitary zones of plants are higher than the maximum allowable concentrations. The reasons for this situation are manifold, but the main one is that the cleaning of industrial gas emissions has not only been neglected for a long time, and the attitude to the issue has implied the ability of the environment to unlimited self-cleaning.

3 Identification of previously unsolved problems Improvement of soda production until recent years has been aimed at improving technology and upgrading the equipment of the main production cycle. The creation of equipment for the protection of the environment was not given much attention. Gases and liquids were cleared only of ammonia to the limits substantiated economically, and not sanitary norms. Only recently, systems for cleaning emissions and utilizing the heat of secondary sources have been developed and implemented. This, in turn, requires the development of scientific principles for the design of devices for cleaning gas emissions of soda production. In addition, the introduction of traditional systems and installations for cleaning industrial emissions require large capital and operating costs. From the technological cycle of soda production are output: gas streams, liquid industrial effluents and solid sludge. When 1 ton of soda ash is produced, the following substances are removed from the technological cycle [2]: 1. Components of gaseous streams: ─ ─ ─ ─ ─

ammonia – 1.5 kg; carbon monoxide – 27 kg; oxides of nitrogen – 0.8 kg; sulfur dioxide – 5.6 kg; dust – 0,4 kg.

2. Liquid industrial effluent: ─ water from water rotation – 5 m3; ─ weakly mineralized runoff – 2 m3; ─ flushing water with calcium chloride and sodium chloride – 2.3 m3; ─ clarified distillation liquid – 9.8–10 m3. 3. Solid slimes: ─ brine cleaning mud (containing calcium carbonate, magnesium hydroxide, sodium chloride, calcium sulfate and water) – 25 kg;

─ small waste of quenching (containing calcium oxide, calcium carbonate and others) – 81 kg; ─ distillery slurry (containing calcium carbonate, magnesium carbonate, calcium oxide, sodium chloride, calcium chloride, calcium sulfate and water) – 250 kg. Annually, soda enterprises withdraw about millions m3 of liquid industrial effluents and gaseous substances, millions of tons of solid waste and dust from the technological cycle. [2]. And in the future it is expected to continue rapid growth in the world scale of industrial production of soda ash, which will inevitably lead to an increase in the amount of waste generated [3]. In comparison with other chemical and petrochemical enterprises soda plants discharge large amounts of harmful emissions into the atmosphere, mainly not related to particularly toxic (dust soda, carbon dioxide, ammonia). Carbon monoxide and a small amount of hydrogen sulphide are also present in the emissions. The emissions from the boiler unit of the soda plant usually contain oxides of nitrogen and sulfur.

4 Research The task of cleaning industrial gas emissions is significantly complicated by the fact that their volumes are dozens, and sometimes hundreds, thousands of m3/h, which makes it difficult to use traditional cleaning equipment. Most of the devices currently used to purify gases from gaseous, liquid and solid impurities are characterized by low capacity, due to the small maximum allowable gas velocities in the apparatus. This is the reason that highperformance devices have large overall dimensions (for example, the diameter of absorption columns can reach 10–12 m), and the costs of their manufacture, installation and transportation are prohibitive. The concentration of ammonia in the gas discharge is within the range of 0.1–0.2 g/m3, and the maximum allowable concentration is 50 mg/m3. The main source of gas emissions of ammonia is the gases after the process of carbonization of the ammoniated brine. At the same time, at the factories there are 4 to 13 second column gas washers. The traditional bubble gunner of second column gas washer consists of eight elements, bottom and lid [2]. The main mass-exchange element of the apparatus is a bubble-pin device, which is installed inside the contact plate. On each plate there are 17 bubble devices and one nozzle for flooding the liquid through a water jacket on an understated plate. In total, in the bubble gunner of second column gas washer in practice, 8 working plates with bubbling devices are used. Multi-stage vortex devices are perspective equipment for cleaning large volumes of industrial gas emissions, including ammonia [1, 4]. A comparative analysis of the parameters of the operation of devices for gas cleaning testifies to the use of hollow vortex devices with low hydraulic resistance, fairly low energy and metal capacity.

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short residence time of phases in the contact zone and a high hydraulic resistance [8]. In addition, existing conventional dust-collecting equipment does not effectively capture particles smaller than 10 μm, and they are largely carried away with the gas stream. These factors necessitate the transition of gas purification systems from the substantial amount of a solid polydispersed phase contained in it to a fundamentally new technology. Comparative dependence of the capture efficiency on the fractional composition of solid particles and aerosols in the gas stream for different types of equipment is given in Table 1. To intensify the trapping of dust, it is necessary to use an intensive mode of interaction of phases with a high turbulence of the streams. Fine dust particles have low inertia, so the cleaning process is possible only in devices with an intensive hydrodynamic mode of operation, for example, such as hollow vortex devices. In a vortex dust collector, as in a cyclone, dust separation is based on the use of centrifugal forces. In vortex dust collectors, a very high purification efficiency is achieved – 99–99.5 % and higher. The device can be used for cleaning gases with a temperature up to 700 °С. Table 1 – Efficiency of dust trapping by various designs of gas cleaning equipment

Type of equipment

Dust settling chamber Cyclone Cyclone with elongated cone Electrofilter Hollow scrubber Venturi scrubber Hose filter Vortex scrubber

Overall efficiency, %

This makes it very promising to use for cleaning large volumes of gas emissions from vortex-type devices. The use of centrifugal separation in vortex devices removes the restriction on the maximum permissible gas velocity and makes it possible to carry out the processes at medium-velocity gas velocities reaching 20-40 m/s. The high throughput of vortex devices in the gas phase causes their small overall dimensions. In addition, the advantages of these devices include low metal consumption, relatively low specific energy costs, stability of operation in a wide range of loads in liquid and gas, and ease of manufacture. Despite the fact that the principles of designing vortextype devices have been developed quite a long time [4, 5], their widespread use in industry is hampered by the lack of reliable and valid methods for calculating the efficiency of gas purification processes taking place in them. Multistage vortex devices are a heat and mass exchange column with contact vortex stages. The contact stage of multi-stage devices is executed in the form of a single vortex stage inside which counter-current motion of phases is realized. In general, in the apparatus phases move the in countercurrent mode. Features of the technology for cleaning gas emissions from ammonia, as well as the operating principle and design of a multi-stage vortex device are described in detail in the following works [6, 7]. A feature of the vortex apparatus is the presence in the working space of a highly developed surface of mass exchange, which includes a drop, film, and foam interface [6]. High relative phase velocities and constant renewal of the phase interface ensure high efficiency of the devices of this design. The coefficient of heat and mass transfer of the apparatus is an order of magnitude higher than in known industrial apparatuses used for the same purposes. This allows you to get the desired result with minimal overall dimensions and metal capacity. Also, among the most important problems of soda production, the process of which is related to storage, processing, packaging, etc., first of all, pollution of air, industrial premises and territories with soda dust. Such technological processes, as loading, unloading, overfilling, sorting are accompanied by the release of dust. Technology dust is very diverse in chemical composition, size, shape and density of particles. The density of the particles of soda ash varies, generally, from 1 000 to 3 000 kg/m3. It contains particles of 3–50 μm in size. The formation of fine soda dust is facilitated by the processes of its mechanical processing, as well as various loading and unloading operations, transportation and storage [8]. To clean the gas of large dust, a washer is usually used, which is a chordal apparatus that is watered. To clean the gas of fine dust it is sent to an electrostatic precipitator, a foam washer or a Venturi scrubber [8]. According to the current schemes for cleaning gases from a solid dispersed phase, there are difficulties associated with cleaning the precipitation electrodes during the operation of the electrostatic precipitator from the settled dust. The main drawbacks of scrubbers when capturing solid dust particles are a large flow of irrigating liquid, a

Efficiency of capture,%

<5 μm

5–10 μm

10–20 μm

20–40 μm

> 40 μm

58.6

7.5

65.3

84.2

97.0

94.5

99.5

100

98.5

100

99.5

100

99.7

99.5

100

99.8

99.9

100

In the vortex dust collector there is no wear of the internal walls of the apparatus, which is due to the peculiarities of its air regime. The device is more compact than other designs of dust collectors. The use of hollow vortex devices in this method of cleaning gas emissions will

Investigation of Operating Processes in Machines and Devices

Figure 2 – The apparatus for studying the work parameters of a vortex apparatus: 1 – vortex device; 2 – the working section, 3 – the droplet separator, 4, 5 - the tangential swirler; 6, 7 – the contact sections; 8 – gas inlet; 9 – gas outlet; 10 – the sampling pipe; 11 – measuring cup; 12–14 – manometers; 15 – fluid inlet; 16 – tank; 17 – centrifugal pump; 18 – flowmeter; 19, 20 – valves; 21 – gate valve; 22 – diaphragm; 23 – gas blowers; 24, 25 – heating element; 26 – psychrometer

reduce the consumption of liquid for wet cleaning. By adjusting the speed of the gas at the inlet to the apparatus, it is possible to ensure optimum operation in the vortex apparatus. The design of equipment for the study of the parameters of the vortex apparatus is shown in Fig. 2.The flow of liquid enters the apparatus through the gas-phase connection. From the holes in the sprinkler, the liquid is sprayed into the working area of the apparatus. The swirling flow of gas interacts intensely with the liquid. Rotating together with the gas-liquid flow, dust particles move to the surface of liquid droplets. Under the action of the centrifugal force, the liquid precipitates on the wall of the apparatus and flows down along it in the form of a film. This creates an additional contact zone of the gas and liquid phases. The gas, passing through the droplet layer, is cleaned of solid impurities, after which it is removed from the apparatus through the upper nozzle. The used liquid is removed through the lower nozzle. The main advantages of this device are high throughput in the gas phase and low hydraulic resistance. These factors necessitate the joint use of already installed cyclones at the enterprises simultaneously with vortex devices for gas purification from cleaning matter in soda plants. In order to pre-clean the large particles of soda, the gas is supplied to the apparatus for trapping large particles, for example, a cyclone. After that, the gas enters the vortex apparatus for wet cleaning from small dust particles. The liquid in the vortex device comes from the condenser. The spent liquid from the dust trap is taken to the evaporation apparatus, where the concentration of the solution is taken, which is then taken to the crystallizer to separate the soda crystals. Water vapor is then fed to the condenser, and then returns to the hollow vortex device (Fig. 3).

Figure 3 – Scheme of cleaning the air flow from the soda dust: 1 – cyclone; 2 – dust collector; 3 – vortex apparatus; 4 – evaporator; 5 – condenser; 6 – input of a dusty gas; 7 – cleaned gas outlet; 8 – outlet of the evaporated solution; 9 – air outlet to the atmosphere; 10 – input of heating steam; 11 – outlet of condensate of heating steam

The proposed gas purification method can also be used in other industries to purge from soluble dust crystals.The use of hollow vortex sludge devices in this method will reduce the consumption of liquid for cleaning from dust. Also, adding a small amount of liquid to the swirler by spraying it, makes it possible to lower the hydraulic resistance of the apparatus. Thus, it is advisable to use the proposed apparatus in this technological scheme. The efficiency of deposition of submicron particles in a device with intensive phase interaction can exceed 95 %.

5 Conclusions The use of the modernized two-stage purification scheme allows efficient air purification from dust of suspended solids. The use of hollow vortex devices in this method will eliminate the problem of clogging equipment and communications with sediments. In addition, the main advantages of vortex devices is the simplicity of manufacturing, installation and maintenance, small overall dimensions, large phase contact surface, high efficiency of trapping fine particles and high gas phase productivity. Using a recycled liquid will result in a lower power consumption of the installation. This makes the installation promising for practical use to improve economic and environmental performance. For the soda industry, the necessity of introducing fundamentally new compact and highly efficient absorbers, capable of working at high L/Q ratio, has been long overdue, providing not only the intensification of gas absorption processes but also the solution of a number of environmental problems of soda production. Thus, the main result of the work is updating of the technology of ammonia and dust emissions, development a new construction of equipment, which contributes significantly to the improvement of soda production as an important sub-sector of the chemical industry.

Journal of Engineering Sciences, Volume 4, Issue 2 (2017), pp. B 1–B 6

References 1. Issledovaniye problem razrabotki, vnedreniya i razvitiya tekhnologiy kompleksnoy zashchity cheloveka pri chrezvychaynykh situatsiyakh. FGU VNII GOChS, Мoscow, 2007, pp. 166 [in Russian]. 2. Tkach, G. A., Shaporev, V. P., & Titov, V. M. (1998). Proizvodstvo sody po malootkhodnoy tekhnologii. KHGPU, Kharkiv [in Russian]. 3. Proceedings of the International Conference “World soda ash”. Riviera, 2007. 4. Sabitov, S. S., Savel’yev, P. I., et al. (1981). Vikhrevyye massoobmennyye apparaty. Obshcheotraslevyye voprosy razvitiya khimicheskoy promyshlennosti, Moscow, NIITEKhIM, Issue 3 [in Russian]. 5. Nikolayev, L. N., Ovchinnikov, A. A., & Nikolayev P. A. (1992). Vysokoeffektivnyye vikhrevyye apparaty dlya kompleksnoy ochistki bol’shikh obyomov promyshlennykh gazovykh vybrosov. Khimicheskaya promyshlennost’, No. 9, pp.36–38 [in Russian]. 6. Moiseev, V. F., Manoylo, E. V., & Hrubnik A. O. (2015). Intensyfikatsiya promyvacha hazu kolon u vyrobnytstvi kal’tsynovanoyi sody. Tekhnologicheskiy audit i rezervy proizvodstva, Kharkiv: Tekhnolohichnyy Tsentr, No. 6/4 (26) [in Ukrainian]. 7. Moiseev, V. F., Manoylo, E. V., & Hrubnik A. O. (2016). The decrease in technogenic load on the environment during the process of absorption of ammonia in soda industry. Journal of Engineering Sciences, Vol. 3, Issue 2, pp. G1–G7. 8. Krasheninnikov, S. A. (1985). Tekhnologiya kal’tsinirovannoy sody i ochishchennogo bikarbonata natriya. Vysshaya shkola, Moscow [in Russian].

Investigation of Operating Processes in Machines and Devices

JOURNAL OF ENGINEERING SCIENCES УРНА ІН

Н РНИХ НАУ УРНА ИН

Н РНЫХ НАУ Web site: http://jes.sumdu.edu.ua

DOI: 10.21272/jes.2017.4(2).b7

Volume 4, Issue 2 (2017) UDC 621.774.5

Alternative technology to manufacture bimetallic products by using self-propagating high temperature synthesis Skidin I. E.1, Kalinin V. T.2, Tkach V. V.1, Saitkhareiev L. N.1, Zhbanova O. M.1* 1

Kryvyi Rih National University,11 Matusevycha St., 50027, Kryvyi Rih, Ukraine; National Metallurgical Academy of Ukraine, 4 Gagarina Av., 49600, Dnipro, Ukraine

Article info: Paper received: The final version of the paper received: Paper accepted online:

Corresponding Author’s Address:

September 20, 2017 November 20, 2017 November 27, 2017

zhbanova.olena@gmail.com

Abstract. Electric welding is usually used for surfacing metal products. This process may be laborious and timeconsuming, which at the same time excludes welding jointing throughout the product surface. The productivity of powder tape surfacing is pretty low, up to 2.7 kg / h, with a melting rate of 13-15 min / h. The use of the selfpropagating high-temperature synthesis for producing a liquid thermite alloy aimed at further surfacing throughout the metal surface of a detail can provide a cost-effective and viable alternative technology for manufacturing bimetallic products. Keywords: high-temperature synthesis, termite, surfacing, bimetal, charge, technology, welding, thermocouple, temperature, mould, alternative resource.

1 Introduction To substantiate the alternative technology, it is necessary to study surfacing on the metal layer of the thermal alloy given by self-propagating high temperature synthesis, as well as to develop a laboratory installation for measuring the temperature fields in the mould at the previous heating of the charge, at the aluminothermic charge combusting, and at obtaining the synthesized thermite alloy. In technology, termites are commonly referred to as powder mixtures of metals with metal oxides, the combustion of which generates a large amount of heat and results a high heating temperature, forms a melt from reaction products and powders of metallic filler [1–5]. The main purpose of termites in their use is the production of metals through the reactions, in which the metal is synthesized from the charge powders. Metals with a high heat formation of oxides with aluminum are required for the exothermic reaction. Metal oxide of low temperature such as iron oxide is a source of oxygen in the exothermic reaction. The heat of exothermic reactions is effectively used in thermite welding. Termite welding is the process of welding metal details with a liquid metal of a given chemical composition obtained from an aluminothermic reaction.

Heat flow of a reaction is sufficient to heat the thermite surfacing alloy up to 3 134 K ( the boiling point of iron) [4]. The actual task is to justify the technological parameters of the surfacing process of a metal layer, a layer of steel or cast iron, resulting from self-propagating hightemperature synthesis; to study the heating kinetics of the surfacing mould prior to the beginning of the melt synthesis, the temperature indices of the process components, the initial surface temperature of the surfacing layer; to develop a technology and a laboratory installation for more than 5 mm thick surfacing metal layer of steel or cast iron produced from a self-propagating hightemperature synthesis.

2 Results The mould for surfacing consists of a sandy-clay shell with a lid. A metal layer for surfacing the thermite alloy is positioned in the mould. According to the model, a certain free volume is formed for the thermite mixture (Fig. 1). The mould is dried at a temperature of 524 K for 1.5 hours in order to remove moisture. To control the temperature in the mould, thermocouples 4 (Fig. 2 a) are installed. The mould is filled with a thermite mixture 2, which is thickened on the vibrating table.

Journal of Engineering Sciences, Volume 4, Issue 2 (2017), pp. B 7–B 10

b a

Figure 2 – Experimental mould: 1 – moulding mixture; 2 –termite mixture; 3 – metal base; 4 – thermocouples; 5 – mould lid

Figure 1 – Experimental mould: a – position of the metal base in the mould on the model; b – sandy-clay mould with a cavity for a thermite charge; c – condensed thermite mixture in the mould; d – mould assembly with an opening for arcing termite and venting gases

A laboratory installation has been designed and installed to study the kinetics of thermal processes in the form for exothermic surfacing. The lab unit includes: a laboratory muffle furnace, a surfacing mould, a controller with a recording device for the kinetic dependences of temperature variations, a set of tungsten-rhenium thermocouples with individual amplifiers and compensators (Fig. 3).

Figure 3 – Experimental laboratory complex: 1 – laboratory muffle furnace; 2 – experimental surfacing mould with thermocouples; 3 – tungsten-rhenium thermocouples BP 5/20; 4 – amplifier of the signal of thermocouples with compensators; 5 – high-speed self-writing device H32

Since the exothermic surfacing process generates high temperatures, tungsten-Rhenium thermocouples BP 5/20 with the maximum range to +2 774 K were used, which were insulated with ceramic tubes with two holes ḓ = 0.3 mm. Thermocouples were connected to a highspeed self-writing device H 320-5. Changing the voltage of the thermocouple indicator is a linear change in the temperature of the alloy. Since the voltage generated by the thermocouple is negligible, it is not possible to apply indicators to the tape of the recorder. The way out of this situation is to use an amplifier for a thermocouple. A circuit and a double-cascade operational amplifier LM 358 have been designed (Fig. 4). The voltage gain can be increased from 50 to 200 times, depending on the position of the regulating resistor. On this basis, the resistance of the variable resistor R 3 is controlled by the graduated scale of the recorder tape. The amplifier tested with a thermocouple has an average sensitivity to the input voltage of 20 mV, resulting in an amplifier output of 3.8 V. B8

Figure 4 – Circuitry of the amplifier

When connected to the thermocouple, its negative output connects to the X 1 connector, and is positive to the X 2 connector. A 5 V power supply can be obtained using a voltage regulator 78 l05. It should also be noted that this circuit can be connected to a power supply of 12 V. To study the thermal distribution in the surfacing process by casting the synthesized alloy, the thermocouples should be placed in the following areas of the form:

Investigation of Operating Processes in Machines and Devices

moulding mixture; under the metal base; over the metal base; in a thermal charge. To determine the time of thermal distribution, the kinetic dependence of the filler form heating on time (temperature of the furnace 874K) was studied. Mould sizes were formed for the study (Fig. 2 b). The prepared mould was heated in a laboratory muffle furnace preheated to a temperature of 874 K. The results are shown in (Fig. 5).

heating rate of the moulding mixture is explained by the redistribution of thermal energy between the termite charge and the mould wall. Thus, it is necessary to heat the mould for 110 minutes in order to achieve the temperature of the termite charge of 800 K. Previous studies and theoretical calculations reveal that the main process parameter is the heating temperature of the termite charge in the exothermic casting process. The temperature of the metal base 630–640 K reached for a period of heating of the mould is sufficient for the process of surfacing. In order to accelerate the mould heating time, when the exposed surfaces were directly contacted with the heated atmosphere of the furnace, a mould with an open metal base in the lower part (Fig. 6) was made, and the temperature in the furnace was raised to 924 K. The time for heating the surfacing mould to 874 K was reduced by 20 %, that is, to 90 min. However, it should be noted that the exposed surface of the metal base in the lower part of the mould significantly changes the self-propagating high-temperature synthesis process. When combustion of the thermite mixture in the 0.5 min from the start of the process is initiated, the temperature of the lower surface of the metal layer starts decreasing significantly to ambient temperature (4–5 ºС) and is kept for 3.5–4 s, as demonstrated in the thermogram Fig. 7 a.

Figure 5 – The heating curve of the form per unit time: 1 – heating the walls of the mould; 2 – heating under the plate; 3 – heating of the thermal mixture over the plate; 4 – heating the thermal mixture in the middle

The graph shows that the temperature of the mould wall after its placing in the furnace is intensively increased. The dynamic temperature control up to 40 min is 13.5 K/min. The heating rate to 3.7 K/min varies from 40 to 80 min. When the mould is still in the furnace, the heating rate increases to 5.3 K/min. The increase in the

Figure 6 - A form with an open metal base in the lower part: 1 – moulding mixture; 2 – termite mixture; 3 – metal base; 4 – opening for ignition of a mixture and an output of gases

Figure 7 – Temperature distribution in exothermic casting a – lower surface of the metal base; b – upper surface of the metal base; c – moulding mixture; d – process charge-alloy medium temperature

Journal of Engineering Sciences, Volume 4, Issue 2 (2017), pp. B 7–B 10

The total combustion time of the termite is 8.5 s, which is evident from the thermogram Fig. 7 b. After that the combustion front reached the surface of the metal layer and its temperature increased to 2 024–2 054 K within 1 s, that is, the termite began to melt. This temperature was kept for 5–7 s leading to the fusion of the liquid phase and the metal layer. In the 15.5 s from the start, the temperature of the layer decreased to the level of crystallization of iron and subsequently decreased at a rate of 354–374 K/s. The temperature of the mould and its changes are shown in the thermogram Fig. 7 c. Within 0.5–1 s from the start of the process, the temperature decreased from 874 K to 724 K, and then at a rate of 284–286 K/s rose to 824 K and was kept until complete crystallization of the metal. The temperature in the first 3–3.5 s did not change on the interface between the termite mixture and the moulding material at a point of a height of ½ of the bulk layer. When approaching the combustion layer to this point, the temperature rose and reached 2 474–2 674 K in 4–5.5 s, which was equal to the combustion temperature of the termite mixture. The allocated heat energy went on melting of the moulding material and its heating. A dense sand and slag deposition was formed on the inner surface

of the mould, which kept the heat energy inside the mould. It should be noted that the exposed lower surface of the metal base accelerates the preliminary heating of the experimental mould in the muffle furnace. At a time, there is cooling of both the moulding mixture and the metal base after the burning of the termite mixture. Similarly, the temperature of the mould from 874 to 724 K and the upper layer of the surface layer from 774 to 514 K is decreased. When the combustion process is completed, the temperature at these points is restored.

3 Conclusions The required time for heating the mould to a temperature of 873 K is 110 min. However, raising the temperature in the furnace to 923 K causes the installation wear and the increase in oxidation of metal powders in the heating furnace. The use of the exposed lower surface of the mould adversely affects the self-propagating hightemperature synthesis process and the temperature of the metal base. This is due to the formation of air flow from the environment into the lower cavity of the form with the jet stream of gases emitted from the surfacing mould through the outlet in the lid during combustion of the termite mixture.

References 1. Kuzmenko, G. V. (2012). New technology of electric arc welding by the rails in the conditions of tram and crane ways. Automatic welding, No. 5, 40–45. 2. Kostiuk, M. D., Kozak, V. V., & Yakovliev, V. O. (2010). Construction and reconstruction of the railway tracks in Ukraine to increase the throughput and introduction of high-speed trains. IES after Ye. O. Paton, Kyiv, pp. 216. 3. Karpushchenko, N. I., Klinov, S. I., Putria, N. N., & Smirnov, M. P. (1999). Railway track. Transport, Moscow, pp. 405. 4. Lonsdale, C. P. (1999). Thermit rail welding: history, process developments, current prac-tices and outlook for the 21st century. Proc. of the AREMA 1999 annual сonf., The American railway engineering and maintenance-of-way association, pp. 2–5. DOI: 10.12691/materials-5-1-2. 5. Okumura, M., Karimine, K., Uchino, K., & Yurioka, N. (1995). Development of field fusion welding technology for railroad rails. Nippon Steel Techn. Rept., Vol. 65, No. 4, 41–49.

B 10

Investigation of Operating Processes in Machines and Devices

JOURNAL OF ENGINEERING SCIENCES УРНА ІН

Н РНИХ НАУ УРНА ИН

Н РНЫХ НАУ Web site: http://jes.sumdu.edu.ua

DOI: 10.21272/jes.2017.4(2).b11

Volume 4, Issue 2 (2017) UDC 621.791

Study of verification and validation of standard welding procedure specifications guidelines for API 5L X-70 grade line pipe welding Qazi H. A. A.* Crescent Steel and Allied Products Ltd., Latifabad, Hyderabad, Sindh, Pakistan Article info: Paper received: The final version of the paper received: Paper accepted online:

Corresponding Author’s Address:

September 29, 2017 November 25, 2017 November 28, 2017

ahadqazi10@yahoo.com

Abstract. Verification and validation of welding procedure specifications for X-70 grade line pipe welding was performed as per clause 8.2, Annexure B and D of API 5L, 45th Edition to check weld integrity in its future application conditions. Hot rolled coils were imported from China, de-coiling, strip edge milling, three roller bending to from pipe, inside and outside submerged arc welding of pipe, online ultrasonic testing of weld, HAZ and pipe body, cutting at fixed random length of pipe, visual inspection of pipe, Fluoroscopic inspection of pipe, welding procedure qualification test pieces marking at weld portion of the pipe, tensile testing, guided bend testing, CVN Impact testing were performed. Detailed study was conducted to explore possible explanations and variation in mechanical properties, WPS is examined and qualified as per API 5L 45th Edition. Keywords: welding procedure specification WPS, welding procedure qualification record WPQR, submerged arc welding SAW, american petroleum institute API, american society for testing materials ASTM, tensile test, guided bend test, charpy V-notch impact test.

1 Introduction Welding procedure specification is a standard guideline used to perform a welding action. A WPS is designed and issued by welding engineer and is used by qualified welding operators and welders to perform welding operation so that in each weld, required mechanical properties can be achieved. In a typical WPS, essential variables material grade, voltage (tolerance of less than or equal to 7 %), current (tolerance of less than or equal to 10 %), welding speed (tolerance of less than or equal 10 % for automatic welding), heat input (tolerance of less than or equal to10%)are given in a range while variables like type of welding process, method of welding electrode diameters, polarity, type of electrode and flux, shield gas type if any used are fixed and cannot be changed once a WPS is qualified. If these are to be changed in any case, a new welding procedure specification is to be made and welding procedure qualification (WPQR) tests have to be performed.

2 Methodology and results To verify mechanical properties mentioned in coil manufacturer mill test certificate, Tensile Test, CVN Impact test samples were cut from as received coil,the testing was performed as per ASTM A370 standard, the testing

results are presented in Table 1 which is complying with table 7, clause 9.7, 9.8 and table 8 of API 5L-45th Edition. After the verification of mechanical properties, Pipe manufacturing using verified coils was done using these steps, Hot rolled coil was charged using charging lever at Spiral SAW pipe mill where first de-coiling was performed through auxiliary driver rollers, three roller leveling at 140 Bar pressure, five roller leveling at 150 Bar pressure, strip was driven further by main driver rollers at 80 Bar pressure, both edges of plate was milled as per weld geometry design given in WPS, pre-bending of plate, three roller bending at 380 Bar pressure to form pipe, inside and outside welding on pipe was performed by qualified welding operators, Online ultrasonic testing of welds, HAZ and pipe body on full length of pipe to detect defects related to weld, HAZ and pipe body, fluoroscopic examination on full length of pipe was performed to verify soundness of the weld, marking of test pieces on inspected OK pipe was done, transverse tensile testing on two specimen were performed at 25 °C to measure ultimate tensile strength picture representation of tensile test specimen, Tensile testing machine, stress-strain diagrams, fracture appearance of tensile test specimen after the test are shown below in Figure 1. Guided bend testing on 4 specimen (cut from weld portion in transverse direction of pipe)two face and two root was performed to bend the specimen at 180 degrees over the mandrel (the mandrel

Journal of Engineering Sciences, Volume 4, Issue 2 (2017), pp. B 11–B 14

B 11

dimension was calculated as per clause 10.2.4.6 of API 5L-45th Edition and then to visually inspect for any cracks occur during bending, CVN impact testing on 9 specimen on weld area and 9 specimen on Heat affected Zone area

at ambient temperature and at 0 °C was performed to measure energy absorbed in Joules during fracture termed as toughness. Testing results of specimen cut from pipe are presented in Table 2.

Figure 1 – Prepared marked tensile specimen (a); fractured tensile specimen (b); fractured tensile specimen cone appearance (c); fractured tensile specimen cup appearance (d)

Figure 2 – Universal tensile testing machine (a); coil tensile specimen stress-strain diagram (b); automatic machine welding tensile specimen A1 stress-strain diagram (c); automatic machine welding tensile specimen A2 stress-strain diagram (d)

Figure 3 – Charpy Impact test machine (a); CVN weld and HAZ test specimen (b); fractured appearance of coil CVN specimen (c); fractured surface of CVN weld specimen (d); fractured surface of HAZ specimen (e)

Figure 4 – Prepared guided bend face specimen (a); guided bend root test specimen (b); guided bent test machine (c); face bent specimen showing no crack appearance (d); root bent specimen showing no crack appearance (e)

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Investigation of Operating Processes in Machines and Devices

Table 1 – Mechanical Properties of As received coil

Procedure

Tensile Test

Test Piece Average Width (mm)

Gauge Length (mm)

Yied Strength (MPa)

Ultimate Tensile Strength (MPa)

Yield Ratio (Yield Ratio / UTS)

Elongation (%)

Sample

Sample Orientation

Test Piece Average Thickness (mm)

Heat No-Coil No. 1

Transverse

17.55

38.10

590

630.82

0.90

37%

Heat No-Coil No. 1

Transverse

17.52

38.05

597

633.67

0.92

39%

Charpy V-Notch Impact Test Heat No-Coil No. 1 Sample Identification

Heat No-Coil No. 2 Heat No-Coil No. 3

10×5×55 Specimen Size (mm)

10×5×55

Energy Absorbed Converted to Full Sized Specimen (Joule)

280

270

> 85 Shear Fracture, %

> 85

267

> 85

Table 2 – Mechanical Properties of welded test specimens for welding procedure qualification record

Tensile Test

Sample Identification

Sample Orientation

Test Piece Average Thickness (mm)

Weld 1

Transverse

17.58

Weld 2

Transverse

Weld 1 Weld 2 Weld 3 HAZ 1 HAZ 2 HAZ 3

Sample Identification

Face Bend Root Bend

Specimen Size- Half Size Reduced Specimen (mm)

Specimen Size

Test Piece Average Width (mm)

Gauge Lengt h (mm)

Yied Strengt h (MPa)

Ultimate Tensile Strength (MPa)

Yield Ratio (Yield Ratio/UTS)

Elongation (%)

38.10

N/A

651.82

N/A

17.52 37.99 50 N/A 651.98 N/A N/A Charpy V- Notch Impact Test 10×5×55 Energy 212 > 85 Absorbed 10×5×55 240 > 85 Convert10×5×55 224 > 85 Shear ed 10×5×55 268 > 85 Fracture, to Full 10×5×55 252 > 85 % Sized Specimen 10×5×55 264 > 85 (Joule) Guided Bend Test 300×50 No cracks and open to surfaces Visual Condition mm defects observed of specimen 300×50 No cracks and open to surfaces defects after bend test mm observed

From the Table 1, it has been observed that tensile strength value of as received plate was lower as compared to the results obtained from test weld test pieces. In addition to the filling material added during welding, since welding is a thermal fusion process, material which was

joined through welding had to gone though heating and cooling cycles that caused the mechanical properties of the material altered as in our case from Table 2, it can be seen tensile strength of the welded specimen has been increased.

Journal of Engineering Sciences, Volume 4, Issue 2 (2017), pp. B 11–B 14

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3 Conclusion The weld metal is comparatively stronger, and the joint properties are controlled by weld metal chemical composition and microstructure. Although the welding wire is generally of a composition that matches that of the parent metal yet alloying elements are intentionally added in welding wires to improve final weldment mechanical properties major improvement in mechanical properties are observed due to the heating and cooling cycle that a material encountered during welding process thus grain

structure of the material has been refined which in result increases ultimate tensile strength and impact toughness. Mechanical Testing has been done against the welding joint made as per welding procedure specification, the results are complying with American Petroleum Institute requirement for weld joint of X-70 grade line pipe PSL 2 welding procedure specification has been validated by Quality Control department and permission to proceed has been given to the production department to continue welding practice as per approved welding procedure specification.

References API 5L 45th Edition Specification for Line Pipe. American Petroleum Institute, 2013. ASTM A370. Standard Test Methods and Definitions for Mechanical Testing of Steel Products. ASTM International. ASME Section IX. QW Welding. ASME International, 2017. Rampaul, H. (2003). Pipe Welding Procedures. Industrial Press, New York, USA. Coryell, K. W. (2005). The Professionalâ&#x20AC;&#x2122;s Advisor on WPS/PQR Cross Reference Tables. American Welding Society, Miami, USA. 6. Pullarcot, S. K. (2002). Practical Guide to Pressure Vessel Manufacturing. CRC Press, Boca Raton, USA. 7. Jeffus, L., & Baker, B. (2016). Pipe Welding. Delmar-Cengage Learning, Inc., Montgomery, USA. 8. Kikani. P., & Shah S. (2015). Comparison of WPS and PQR for Pressure Vessel Welding. LAP Lambert Academic Publishing, Saarbrucken, Germany. 1. 2. 3. 4. 5.

B 14

Investigation of Operating Processes in Machines and Devices

JOURNAL OF ENGINEERING SCIENCES УРНА ІН

Н РНИХ НАУ УРНА ИН

Н РНЫХ НАУ Web site: http://jes.sumdu.edu.ua

DOI: 10.21272/jes.2017.4(2).b15

Volume 4, Issue 2 (2017) UDC 621.791.927.5

The hypothesis of formation of the structure of surfaced metal at the surfacing based on the application of the prognostic algorithm of control the electrode wire speed Lebedev V. A., Novykov S. V.* Paton Electric Welding Institute of the National Academy of Sciences of Ukraine, 11 Bozhenka St., 03680, Kyiv, Ukraine Article info: Paper received: The final version of the paper received: Paper accepted online:

Corresponding Author’s Address:

September 13, 2017 November 25, 2017 November 28, 2017

novykov76@ukr.net

Abstract. The growth of a drop in the process of surfacing by a consumable electrode is characterized by a linear dependence of the current change on time. A hypothesis has been put forward, according to which a reduction in the feed rate of the electrode wire to zero in this time interval will substantially reduce the spraying loss and improve the formation of the surfacing roller. For the implementation of which, the use of regulators with a typical law of regulation is proposed, but not according to the current value of the arc current, but according to the forecast. A key feature of these researches is a realization given surfacing process with the imposition of external mechanical oscillations with specified amplitude-frequency characteristics on the welding bath. Analytical calculation of the transfer function for the prognostic PID regulator with the simplest linear prediction taking into account the oscillation of the weld pool is given. Keywords: prognostic regulator, welding pool oscillations, surfacing.

1 Introduction It has been experimentally established that at the moment of the drop growth, the arc current changes linearly. If the wire feed speed is reduced to zero during this period, the liquid bridge period will reduce by 1.7 times at compared to the surfacing mode with a constant wire feed speed. The minimum short-circuit current is reduced by 20 %, that is followed the reduce of the metal spraying loss and the introduced heat quantity into the base metal. The wire feed pulses frequency should be close to or equal to the transfer drops frequency to the weld pool. This mode is provided by an electrode wire feed control system based on automatic controllers. The use of automatic regulators in the modern industry is due to their simple design and application. In welding industry, they are used both for the control and automation of the welding process itself, and for the consumables production, for example, electrodes. Work [1] it is shown that the wide application of classical PID regulators in the automatic control system of an electric furnaces of resistance for the electrodes production does not fully provide performance of the static and dynamic parameters due to the furnace parameters drift. To solve this problem, it is proposed a multiprocessor adaptive control system introduction where in the basic circuit is applied the regulator of a state, the method of standard coefficients - as an adapter in the corresponding

contour, and the least-squares method - as an identifier. This adaptive control system is implemented on the Linux operating system platform. The control systems based of automatic regulators are rising an efficiency enhance of the widely used welding technologies in the industry. So, in work [2] at the development of the model of single-pass automatic argon-arc welding of butt joints made of stainless steel, the control system for root width is built on the basis of a PID controller controlling the welding current according to a given law. The coefficients of the PID controller are determined by the CHR method (Chien, Hrones, Reswick), which allows to obtain a small overshoot and a fast transient process. Moreover, in addition to the width control of the seam root, a system for stabilizing the welding speed on the basis of the PID regulator is built. In work [3] results of researches by perfection of welding technology of angular seams by curvilinear trajectory by means of the welding robot are resulted, where on a basis of the PID regulator the complex of welding speed regulation has been created. The input signal was the preassigned welding speed, and the output signal – the robot center speed. The regulating coefficients were determined experimentally. The results of the experiments showed that the welding speed adjustment by the PID controller made it possible to carry out the welding process with any given curvature radius without significantly the weld-

Journal of Engineering Sciences, Volume 4, Issue 2 (2017), pp. B 15–B 18

B 15

ing speed reducing, that is the efficiency of welding operations significantly is increased. The authors of [4] studied the use of the PID regulator at automatic welding; the aim was to control the weld pool protection (SMAW process) as an arc current function, which was determined by the deviation from the set value of the feed rate of the electrode wire. The working of the PID controller was obeyed by the GA algorithm (genetic algorithm). The PID controller coefficients were selected during the simulation process. The monitoring and control of the welding process's energy parameters, such as current and voltage, are currently implemented in the form of separate control units [5] and monitoring systems for the output current and voltage values in the power supply design. In work [6] some features of designing modern power supplies with microprocessor control are given. A feature of such sources is the application in their design instead of the wide-pulse modulators of the Fuzzy controller with a special program generates the set values of the output current and voltage through power switches. These fuzzy controllers can be used as PID regulators not only for current and voltage, but also for other welding process parameters, for example, temperature. The control coefficients are determined by means of the function Fuzzy Logic- an algorithm of multipara meter logic. In work [7] the PID controller, applied as part of the underwater welding machine and controlled by Fuzzy Logic algorithms was presented, it is made possible to effectively control the welding process parameters on the assumption of the specified parameters of the weld bead geometry. As can be seen from the above, recently the control on a base of PID controllers of various technological processes are provided with complex algorithms, of which Fuzzy Logic and GA algorithm are widely used. The comparative analysis of GA - algorithm is described in detail in [8]. At the same time, the authors of [9] believe that it is possible to significantly improve the efficiency of algorithms of standard regulators without resorting to the use of expensive and complex control systems. To do this, it is enough to modify them insignificantly so that the control is not performed according to the current value of the output quantity – Iarc(t), but according to the forecast – Iarc(t + τfr), where τfr is the time through which the control error occurs. The prognostic regulator consists of 2 parts - a regulator with a typical law of control W(p) and a previous forecast element with a transfer function Wfr(p) or some nonlinear function f(Iarc,t). The element has a memory into which the given linear law of arc current change is introduced – Iarc (t) = А + Io, where A and Io are given constants. By determining the value of the difference Iarc (t) – Iarctec(t), where Iarctec(t) – law of variation of the current value of the controlled variable, the forecasting element converts the value of this difference into a regulation error signal – ɛ = Iarc (t) – Iarc(t + τfr), expected through the regulation time τfr, according to which, in accordance with the adopted typical law, a regulating acting is formed

B 16

 0 ;  fr  0 ; Vwf  0 ;  f (t );  fr  0 ; Vwf  0 ,

 

where Vwf – wire feed speed; f(t) – specified control algorithm. As is known, when surfacing in a carbon dioxide environment, one of the significant drawbacks is the large spattering loss, and at the external oscillations are applied to the weld pool melt, this one only increases. The main cause of the splashing is considered to be a burst of the bridge, which is characterized by a certain value of the current that connects a drop of molten metal to the electrode wire end. Then using the prognostic regulator, it can be set the wire feed mode so that during the growth period of the drop the feed rate is zero, and the drop size is determined by the specified amplitude-frequency characteristics of the weld pool oscillation. The dependences of the arc burning time and the short circuit time on the prescribed law of weld pool oscillation will obtain analytically; on the basis of there the work algorithm of the prognostic regulator can be predetermined.

2 Results The following expression of the arc current at the surfacing with weld pool oscillations according to the law ψ(t) = 2πfopt (Fig. 1) was obtained [10], where fop – given frequency of weld pool oscillation, dependent on the welding speed: 3

I arc  I sc  Dlarc 8 ,

(1)

where Isc [А] – the short circuit current; D [А/m] – coefficient of proportionality, determined experimentally as a function of the welding current; larc – length of the arc, in the conditions of external oscillations defined as [11]: 

t sr

l arc   e  , where   a  tg (2fop ) [m] – amplitude of oscillation of the welding arc; tsr [s] – arc self-regulation time; θ [s] – the self-regulating constant of arc; a [m] – horizontal distance from the oscillation axis to the weld pool; τ [s] – the arc burning time to short circuit.

Figure 1 – Scheme to explain the dependence of the arc length on the frequency characteristics of the weld pool oscillation

Then for the time interval of drop growth we can write: 3

t   sr  8 A arc  I 0  I sc  D a  tg (2f op arc )e   ,  

Investigation of Operating Processes in Machines and Devices

(2)

whence it can be found τarc – interval of arc burning time during which the drop growth occurred (τ > τarc), but the dependence of the arc current on time was linear – Iarc (t) = А + Io. This equation for τarc is transcendental and can only be solved approximately. In view of the foregoing, for the simplest linear forecast the transfer function in the general form will be: Wpr(p) = 1 + pτfr = 1 + p(τarc + mT), where p – complex variable; Т = τarc + τsc – arc burning period; τsc – shortcircuit time; m – natural number. The time τsc is determined from the current density formula obtained analytically as well [10]:

j 3

neel  a  tg (2f op sc )e



t sr



(3)

where j [А/m2] – short circuit current density; n – natural number, increasing with increasing j; eel – electron charge; λ [W/m·K] – thermal conductivity coefficient; K [J/K] – Boltzmann’s constant. Whence:

 sc 

the current Iarc = 180–200 А, when surfacing the electrode wire Sv08G2 with a diameter of 1.2 mm in СО2. The use result of the prognostic regulating is to reduce the splashing (loss) of the electrode metal by 10–12 % in comparison with conventional systems, as well as some improvement in the shape of the weld bead, which can be seen in the Fig. 3 of the compared rollers photos.

   3ne el   1 arctg  . t 2f op  sr     aje K 

Figure 2 – The oscillogram of the impulse speed of feed with an ordinary regulator (a) and at the predicativ (prognostic) regulation (b): 1 – impulse; 2 – pause; 3 – reverse

(4)

Then the transfer function, for example, of the prognostic PID controller will be represented by the following expression:

PID

 p   WPID  p W pr  p  

  1  k p 1   TD p  1  p  arc  m arc   sc  ,   TI p

(5)

where kp – coefficient of regulator transfer; ТI – integration time constant; ТD – differentiation time constant. In accordance with obtained the expression (5), an additional link WprPID (p) was introduced into the regulator of the electric drive of the feed mechanism synthesized by [12], which makes it possible to substantially increase the productivity of the electrode wire supply system generally, and consequently to increase the efficiency of surfacing process control, including with controlled oscillations of the weld pool. Partial confirmation of the obtained conclusions for the development of a prognostic regulator with a period of Т = 0.05 s (data of [13]) can be seen in Fig. 2, where the wire feed speed oscillograms have been presented for comparison, at there are providing integral the value of

Figure 4 – The characteristic surfacing beads obtained by using various methods of regulation for feeding the electrode wire with a prognostic regulator (19) and an ordinary regulator (20)

3 Conclusions In order to reduce the metal spattering at the surfacing on a direct current with external oscillations of the weld pool, carried out by a predetermined law, the hypothesis of using predictive regulators based on widely applicable regulators (PI, PID, P) with optimal control algorithms has been put forward. The analytical equation for calculating the drop growth time and the expression for the short-circuit time interval are presented on the basis of which the transfer function of the predictive PID controller was calculated. These results have in the main theoretical character, that cause to the further experimental researches to verify the obtained analytical dependencies with the experimental data.

Journal of Engineering Sciences, Volume 4, Issue 2 (2017), pp. B 15–B 18

B 17

References 1. Smirnov, M. A. (2012). Razrabotka multiprocessornoy sistemy adaptivnogo upravleniya elektricheskimi pechami soprotivleniya [Development of a multiprocessor system for adaptive control of electric furnaces of resistance: thesis of the candidate of technical sciences dissertation], Ivanovo, pp. 20 [in Russian]. 2. Perkovskiy, R. A. (2010). Razrabotka phisiko-mathematicheskih modeley i mikroprocessornyh sistem kontrol’a i upravleniya processom arghonodugovoy svarki tonkostennyh izdeliy otvetstvennoho naznacheniya [Development of physical-mathematical models and microprocessor systems for monitoring and controlling the process of argon-arc welding of thin-walled products of responsible designation: thesis of the candidate of technical sciences dissertation], Moscow, pp. 17 [in Russian] 3. Cuong, N. D., & Lubenco, V. N. (2009). Soverchenstvovanie processa svarki uglovyh schvov krivyh i gofrirovanych konstrukciy sudna mobil’nym svarochnym robotom [Improvement of the process of fillet welding of bent and corrugated ship constructions with mobile welding robot]. Vestnik of Astrakhan State Technical University. Series: Marine Engineering and Technologies, No. 1, 66–71 [in Russian]. 4. Huang, Y.-W., Tung, P.-C., & Wu, C.-Y. (2007). Tuning PID control of an automatic arc welding system using a SMAW process. The International Journal of Advanced Manufacturing Technology, Vol. 34, Issues 1–2, No. 8, 56–61. 5. Chichicalo, N. I., Vinnichenko, N. G., & Tomilin ,E. M. (2009). Proektirovanie blokov formirovaniya zakonov regulirovaniya dl’a priborov kontrol’a i upravleniya tehnologicheskimi processami [Control law preform blocks design which use in control and monitoring devices of the manufacturing methods]. Scientific Herald Donetsk national technical the university, Vol.148, 69–78 [in Russian]. 6. Sergeev, P. (2009). Osobennosti proektirovaniya istochnikov pitaniya svarochnoy dugi s mikroprocessornym upravleniem [The features of designing a power supplies for a welding arc with microprocessor control]. Power electronics, No. 5, 94–97 [in Russian]. 7. Omajene, J. E., Kah, P., Wu, H., Martikainen J., & Izelu, C. O. (2015). Intelligent control mechanism for underwater wet welding. International Journal of Mechanical and Applications, Vol. 3, Issue 4, No. 8, 50–56. 8. Chopra, V., Singla, S. K., & Dewan, L. (2014). Comparative Analysis of Tuning a PID Controller using Intelligent Methods. Acta Polytechnica Hungarica, Vol. 11, No. 8, 235–249. 9. Pikina, G. A. (2014). Realizaciya principa upravleniya po prognosu v avtomaticheskih sistemah reguliovaniya [An introduction of the management principle by the forecasting in the automatic systems of control]. The Proceedings of the 12th All-Russian Meeting on Governance problems VSPU-2014. Мoscow, The Institute of Management Problems, pp. 200–211 [in Russian]. 10. Lebedev, V. O., Novykov, S. V., Drahan, S. V., & Simutienkov, I. V. (2017). Matematisheskaya model’ processov svarki i naplavki s upavl’aemymi izmeneniyami vyleta elektrodnoy provoloki [Mathematical model of welding and surfacing process with controlled changes in the outlet of the electrode wire. Collection of Scientific Publications, Mykolaiv, No. 1, 48–54 [in Russian]. 11. Leskov, G. I. (1970). Elektrisheskaya svaroshnaya duga [The electric welding arc]. Mashynostroyeniye, Мoscow, pp. 177–179 [in Russian]. 12. Lebedev, V. A., Guly, M. V. (2014). Bystrodeystvuyuschiy ventel’niy elektroprivod dl’a oborudovaniya mhanizirovannoy dugovoy svarki [The high-speed valve electric drive for the equipment of the mechanized arc welding]. Mechatronics, Automation, Control, No. 6, 47–51 [in Russian]. 13. Potapievsky, A. G. (2007). Svarka v zasshitnyh gazah plavyasshimsya elektrodom [The welding in protective gases by a melting electrode]. Welding in active gases. Kiev, Ekotehnologiya, Vol. 1, pp. 192. [in Russian].

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Investigation of Operating Processes in Machines and Devices

JOURNAL OF ENGINEERING SCIENCES УРНА ІН

Н РНИХ НАУ УРНА ИН

Н РНЫХ НАУ Web site: http://jes.sumdu.edu.ua

DOI: 10.21272/jes.2017.4(2).b19

Volume 4, Issue 2 (2017) UDC 66.074.1:[534.1+532.58]

Static calculation of the dynamic deflection elements for separation devices Pavlenko I. V.*, Liaposhchenko O. O., Demianenko M. M., Starynskyi O. Ye. Sumy State University, 2 Rymskogo-Korsakova St., 40007, Sumy, Ukraine Article info: Paper received: The final version of the paper received: Paper accepted online:

Corresponding Author’s Address:

September 14, 2017 December 2, 2017 December 4, 2017

i.pavlenko@omdm.sumdu.edu.ua

Abstract. The following paper considers the influence of acoustic oscillations on multiphase flows on their suspended particles, which can be destroyed or coagulated by vibrations. Considering this, the method of extension of application range of the dynamic separation element as vibrocoagulants due to the use of hydroaeroelasticity phenomena, namely flutter, has been proposed. There were considered the problems of development an engineering method for calculating dynamic separation elements, the main of which is the analytical solution of the hydroaeroelasticity problem. This work takes the first step to its development, considering the previous elastic elements deformation that has a significant effect on the flutter frequency. The state of their static equilibrium was conducted with the use of analytical dependencies of the finite element method. The bimodal finite elements with six degrees of freedom were used for dynamic deflection elements. As the result, there was determined the stiffness of pre-deformed plates and their maximum and minimum possible deflections. The functions of the median surface deflection in the form of a cubic polynomial were used in the model. In particular, there were considered the peculiarities of numerical modelling of coupled problems of gashydrodynamics flows and structural dynamics using the ANSYS Workbench, namely Fluent Flow and Transient Structural modules, which are combined with System Coupling. Also, the peculiarities of different approaches to multi-phase flow modelling are indicated. They are interesting not only by distribution of particles in the stream core, but also by the entrapped liquid film motion on the deposition surfaces. Keywords: gas-dispersed flow, hydroaeroelasticity, preloading scheme, static load, stiffness matrix, wall film, boundary conditions, column vector, displacement.

1 Introduction Considering the ratio of the specific energy consumption and separation efficiency of gas-disperse flows, the methods based on the use of inertia of particles (droplets) suspended in the gas-liquid flow [1], which is caused by a change in the motion direction of the gas-liquid flow, are optimal, and the deposit occurs on the surfaces of walls of the separation channels or deflection elements. The main drawback of this method is the secondary splashing, resulting from a possible increase of flow velocity to a critical value and disruption of the trapped liquid from the deposit surfaces, followed by the introduction of highly dispersed particles. Herein an increase also occurs in the hydraulic resistance, and therefore the actual task is to avoid these modes, which are realized in dynamic separation elements [2, 3]. These elements work as an automatic control system, in which the regulating action is elastic forces, and the object of regulation is the hydraulic resistance. Under the fluviation directed into channels with

elastic plates, hydrodynamic pressure is created, and in the walls of a channel the inertial stresses rise and change the surface form. In order to create the engineering method for calculation of separation elements of this type, it is necessary to solve a complex problem of the hydroaeroelasticity, which analytical solution is difficult, and sometimes even impossible without an introduction of simplifications and assumptions. Today, considering the high development of computer equipment, the software based on the finite volume method and the finite element method are used very often for its solving. But even they have their limitations. Let’s consider the example of the ANSYS Workbench software suite, in which it is possible to solve the hydroaeroelasticity problem using the Fluent Flow (Fluent) and Transient Structural modules, which combination is carried out by means of System Coupling [4, 5]. Taking into account the fact, that in the research of separation elements not only the plug flow particle distribution is of interest, but also the motion of the trapped liquid film along the deposition surfaces.

Journal of Engineering Sciences, Volume 4, Issue 2 (2017), pp. B 19–B 24

B 19

Such calculation is possible in two cases, with a detailed solution of the wall area with the help of an exhausted volumetric grid, or by means of using the Eulerian wall film model [6, 7]. Considering the peculiarity of the use of dynamic grids in these cases, the calculation will be computationally expensive, and therefore the optimization of channel design by constructing response surfaces and applying optimization algorithms is not appropriate in this case [6]. Therefore, it is important to develop a methodology for separation channels survey. The solution of the optimal channel profiling problem usually presents considerable difficulties, therefore, in practice, approximate methods are used, based on physical concepts of the hydro- dynamically expedient distribution of velocities of the gas flow in the cross section and in the near-wall areas of the channel [8]. The separation channel is profiled by successive approximations, starting with the orienting constructions, according to the main requirements to the form and the ratio of the parameters of certain sections, the creation of conditions for inertial deposition of the disperse particles in the change of the flow direction of the solid phase flow, with the required average flow velocity of the passage sections, and then the lines embossing the channel shape are smoothed to prevent the combination of sections with a hopping in the radiuses of curvature in the flow. After preliminary construction of the curvilinear separation channel, we conduct the calculation of speed distribution in the channel computational region and on the walls, which limit it, and, if necessary, the channel form is further adjusted, in accordance with desired changes in the resulting velocity distribution. Particular attention during the profiling is required for the diffusive sections of the channels, where losses may be due to the separation of the flow. The possibility of separation limits the velocity gradient on the channel walls [9]. This paper considers the construction of dynamic separation elements, elastic elements of which are in the form of an inclined parabolic semi-cylinder [2] (Figure 1).

namic forces and inertia forces. As a result of the vibration of the elastic deflection elements, there will also be oscillations of the gas-liquid flow, as a result of which the droplet may become concentrated in the liquid, and, consequently, the efficiency of the separation increases. Thus, due to the use of flutter or buffeting, the use of dynamic separation devices is possible. It should be noted that the acoustic coagulation of droplets is one of the traditional ways of improving separation efficiency. When applying acoustic oscillations with a certain frequency on the gas dispersion flow, intensive mechanical vibrations of highly dispersed suspended liquid droplets in the gas dispersion flow occur, resulting in a sharp increase in the number of their collisions. But the opposite effect of overlaying acoustic vibrations, in particular, the increase of the dispersion of the liquid phase, can be observed [11]. Therefore, it is necessary to know the specific frequency of oscillations in which there is a coagulation of suspended particles in the liquid. For the case of fluctuations of the gas-liquid flow caused by the action of sound waves, developed calculation methods that are well-matched with experimental results [12, 13]. Considering the foregoing, as in the case of acoustic vibratory coagulation, in order to achieve a positive effect on the oscillations imposed on the flow, it is necessary to know the optimum frequency thereof, which depends on the dispersion of the liquid phase. Whereas, the value of the flutter frequency depends on the geometric and elastic characteristics of the baffle elements. As can be seen from Figure 1, the elastic elements of the channel are predeformed, which means that they generate stresses, which increases their rigidity and consequently increases the flow rate at which the flutter can occur. Therefore, the purpose of this paper is to conduct a static calculation of dynamic deflection elements of separation devices to research the previous stressed state.

2 Results The previous deformed state of the dynamic deflection element of the separation device is modelled using analytical dependencies of the finite element method. In particular, the dynamic deflection element is represented by two-node finite element e (i, j) with six degrees of freedom [14]. The design scheme of the preliminary deformed state of the dynamic deflection element of the separation device is shown in Fig. 2.

Figure 1 â&#x20AC;&#x201C; Design scheme of the dynamic deflection element of the separation device

By virtue of the fact that fluviation changes the channels form that causes the change of flow parameters, static and dynamic hydroaerostrances will occur [10], among which the greatest interest will be represented by flutter and buffeting associated with the oscillating motion, when an essential role is played by elastic, aerody-

B 20

Figure 2 â&#x20AC;&#x201C; Design scheme of the preloading dynamic deflection element of the separation device

Investigation of Operating Processes in Machines and Devices

The local coordinate system xl - yl is associated with the undeformed middle surface of the dynamic deflection element, the global coordinate system x - y - with the fixed body. The model provides the use of the deflection function of a median surface in the form of the cubic polynomial, presented in a matrix form:

y l  xl   U 0l ,

(1)

where {U}0l = {y10l, θ10l, y20, θ20l}T – the column-vector of nodal displacement; {Ф} – row-vector of form orthogonal functions (interpolation matrix):  1 yl  1  3

x l2 L2

2

x l3 L3

;

x x2 x3  1 l  L  l  2 l2  l3 L L  L 2 3 x x  2 yl  3 l2  2 l3 ; L L  x l2 x l3   2 l  L   2  3  ; L   L

 ;  

(2)

Cl i , j 

C U 0  F 0 ,

(6)

where {U}0 = {x10, y10, θ10, x20, y20, θ20}T – the column vector of the nodal displacement {F}0 = {X10, Y10, M10, X20, Y20, M20}T – vector of summarized nodal forces with components along the axis x (X10, X20), y (Y10, Y20) and moment (M10, M20); [C] – the global stiffness matrix. The transition from the local to the global matrix of rigidity is carried out due to the next formula:

cos 0  sin  0   0 T     0  0   0

(7)

 1 d  U l  d 2 U l dx, (4) EI  U l i U l j 0 2  dxl2  dxl 2

where E – Young’s modulus; I = b3h/12 – – moment of cross section inertia for the rectangle cross section plate with height b and thickness h. The last formula does not consider the energy of the longitudinal deformation of the dynamic deflection element due to its sufficient flexibility, and the local stiffness matrix takes on the following form:

 sin  0 cos 0 0 0 0 0

0 0 0 0 1 0 0 cos 0 0 sin  0 0 0

0 0 0 (8) ; 0 0  1

0 0 0  sin  0 cos 0 0

[C]El – the local stiffness matrix (5), expanded to size 6×6 by inputting values that correspond to longitudinal deformation:

(3)

where {F}0l = {Y10l, M10l, Y20l, M20l}T – vector of summarized forces, the elements of which are transverse forces Y10l, Y20l, applied in the nodes i, j, and the correspondent moments M10l, M20l; [C]l – a local stiffness matrix whose elements are defined as second derivatives by the corresponding summarized displacements from the quadratic form of the plate deformation potential energy: 2

In the global coordinate system x - y matrix equation of elastic equilibrium has the form similar to the formula (3):

where [T] – transformation matrix:

C l U 0l  F 0l ,

(5)

C   T T C lE T ,

L – – plate length; y10l, y20l – nodes transverse displacement i, j; θ10l, θ20l – turn angles of cross-sections. The index “0” indicates the consideration of the static equilibrium condition; the index “l” corresponds to the local coordinate system; indices “1”, “2” indicate the belonging of a physical quantity to nodes i, j, respectively. The connection between displacements of the deflection element and the forces that caused its deformation is determined by the matrix equation of the elastic equilibrium:

6 L  12 6 L   12  6l 4 L2  6 L 2 L2  C l  EI3  . l  12  6 L 12  6 L  2 2   6L 2L  6L 4L 

C lE

 EA  L   0   0   EA   L  0    0 

12EI L3 6 EI L2

6 EI L2 4 EI L



12EI L3 6 EI L2

6 EI L2 2 EI L



EA L 0

0 12EI L3 6 EI  2 L



0 EA L 0 0

0 12EI L3 6 EI  2 L

  6 EI   L2  (9) 2 EI  L ;  0   6 EI  2  L  4 EI   L  0

A = b·h – plate cross-section area. The case of a flexible deflection element allows not to consider in formula (9) the extension stiffness EA/L. Taking account of the kinematic boundary conditions for the node i (x10 = y20 = 0; θ10 = 0) allows to expand the equation (6) of the elastic equilibrium of the dynamic deflection element into two matrix equations - separately for the nodes i and j:

Journal of Engineering Sciences, Volume 4, Issue 2 (2017), pp. B 19–B 24

C i U 0 j  F 0i ; C j U 0 j  F 0 j ,

(10)

B 21

The final equation of an elastic equilibrium that determines the previous deformed state of a dynamic deflection element is the equation (6) for the following formulas of the global stiffness matrix [C] and the nodes displacement vectors {U}0 and of the generalized forces {F}0 in accordance with formula (14):

where the next descriptions are comprehended:

 12 sin 2  0 EI  C i  3   6 sin 2 0 L   6 L sin  0 

 6 sin 2 0  12 cos  0 2

 6 L cos 0

6 L sin  0   6 L cos 0  ; 2 L2 

 12 sin  0  6 L sin  0  (11) 6 sin 2 0 EI  2 C j  3  6 sin 2 0 12 cos  0  6 L cos 0  ; L  6 L sin  0  6 L cos 0  4 L2    X 10   X 20   x20      F 0i   Y10  ; F 0 j   Y20  ; U 0 j   y20 . M  M     10   20   20  2

The first equation of formula (10) allows to determine the internal forces and the moment that become in fixing the deflection element in the body of the separation device:  12sin  0  X 10   EI    Y10   3   6 sin 2 0 M  L   6 L sin 0  10   2

 6 sin 2 0  12 cos  0  6 L cos 0 2





6 EI 2 x20 sin 2  0  y20 sin 2 0   20 L sin  0 ; L3 (13) 6 EI Y10   3 x20 sin 2 0  2 y20 cos2  0   20 L cos 0 ; L 2 EI M 10   2 3 x20 sin  0  3 y20 cos 0  2 20 L . L





The second equation of formula (10) determines the internal forces that effect the free edge of deflection element as a result of its previous deformation (during the assemble). Further on, the matrix [C] j is chosen as the main stiffness matrix of the system, and the second equation (10) – the equation that determines the deformed state of the dynamic deflection element:  12 sin  0  X 20   EI    Y20   3  6 sin 2 0 M  L  6 L sin  0  20   2

6 sin 2 0 12 cos  0  6 L cos 0 2

 6 L sin  0   x20     (14)  6 L cos 0   y20  ,   4 L2   20 

or in expanded form:





6 EI 2 x 20 sin 2  0  y 20 sin 2 0   20 L sin  0 ; 3 L 6 EI (15) Y20  3 x 20 sin 2 0  2 y 20 cos2  0   20 L cos 0 ; L 2 EI M 20   2 3 x 20 sin  0  3 y 20 cos 0  4 20 L . L X 20 





In the second equation (10) і and in the subsequent index “j” is not specified, and the index “20” is replaced by “0”.

B 22

 6 L sin  0    6 L cos  0  ;  (16) 4 L2 

The components of displacement {U}0 are geometrically determined by the following correspondences:

x20  B  L cos  0 ;

6 L sin 0   x10     (12) 6 L cos 0   y10  ,  2 L2   10 

or in expanded form: X 10  

 12 sin2  0 6 sin 2 0 EI  C   3  6 sin 2 0 12 cos2  0 L  6 L sin  0  6 L cos  0  x  X 20   20    U 0   y20  ; F 0   Y20  . M     20   20 

y20  L sin  0 

H ; 2

(17)

H   tg 0  , B  

 20  arctg

where angle θ20 is determined approximatively for the parabolic plate bending; width B for the deformed plate is in the range (Bmin, Bmax) the limiting values of which are determined by the following correspondences:

Bmin  L  Bmax

H ; 2

(18)

H2 .  L2  4

The least value Bmin corresponds to the condition of the maximum possible deformation of the element, the largest value Bmax is the rotation of the straight position element.

3 Discussion The above-described static analysis mathematical model of the previously deformed dynamic deflection element of the separation device is reliable for the deflection forms of the middle surface that is interpolated by a quadratic or cubic polynomial. The transition to a two-dimensional formulation is substantiated for the case of setting external forces as a result of pressure field integrating along the plate height. Further on, there is going to be proposed the ways of updating the initial parameters of this model and identification of unknown parameters – model’s internal variables – in accordance with available experimental data and the results of numerical simulation based on the use of both the regression analysis and artificial intelligence systems, particularly artificial neural networks. In general, the work’s results may be aimed at improving the following tasks approaches:

Investigation of Operating Processes in Machines and Devices

─ the expansion of understanding of the theoretical foundations of separation processes of gas-dispersed systems in apparatuses with intensive hydrodynamic regimes; ─ analysis of implementation of the physical conditions and formation models of gas-dispersed systems; ─ analysis of mechanics and dynamics of the turbulent gas-dispersed flows; ─ formulation of theoretical and practical problems of continuum mechanics and separation processes of the gas-dispersed flows; ─ definition of the main methods to increase energy efficiency and the separation value of the modular separation devices.

4 Conclusions The possibility of extending the dynamic separation elements application through the use of aero-hydroelastic effects, namely flutter, is revealed. For this purpose, a research of the static equilibrium condition of elastic deflection elements was conducted, because their pre-deformation has a sufficient effect on the flutter frequency. The stiffness of pre-deformed, their maximum and minimum possible deflections are determined. Hereafter, it is planned to conduct research aimed at solving the stationary problem of aero-hydroelasticity of separation devices dynamic deflection elements. This problem can be solved in stationary and nonstationary formulations. Herewith, the analysis of the separation device deflection element deformation as the result of gas-liquid flow action should be based on the determining and further research of equation of plate flexural strain

relative to the predetermined in this article static strained condition in accordance with the calculation scheme given in the Figure 2. It is also necessary to analyze the dynamics of the separation device deflection element with respect to the position of the static equilibrium condition defined above, as well as plates dynamic equilibrium, including the determination of the optimal geometric dimensions that will provide the oscillation frequency of the element, which will coagulate the liquid droplets as a result of collision with the deflection elements of separation device.

5 Acknowledgements Close cooperation between the Processes and Equipment of Chemical and Petroleum-Refineries Department and the Department of General Mechanics and Machine Dynamics allows carrying out the static calculation of the dynamic deflection elements for separation devices as a result of interdisciplinary research in chemical and petroleum industry within the following research commissioned by the Ministry of Education and Science of Ukraine: “Development and implementation of energy efficient modular separation devices for oil and gas purification equipment” (No. 0117U003931) [15]. This research project is aimed at im-proving the technology of inertia-filtering separation of two-phase flows, modelling of dynamic processes of separation of heterogeneous systems with the analysis of the vibration influence (acoustic oscillations) and combined heat and mass transfer, the development and implementation of energyefficient modular separation devices.

References 1. Liaposhchenko, O. O., Sklabinskyi, V. I., Zavialov, V. L., Pavlenko, I. V., Nastenko, O. V., & Demianenko, M. M. (2017). Appliance of Inertial Gas-Dynamic Separation of Gas-Dispersion Flows in the Curvilinear Convergent-Divergent Channels for Compressor Equipment Reliability Improvement. IOP Conference Series: Materials Science and Engineering, Vol. 233. DOI: https://doi.org/10.1088/1757-899X/233/1/012025. 2. Liaposhchenko, O. O., Pavlenko, I. V., Nastenko, M. M., Usyk, R. Yu., & Demianenko, M. M. (2015). Sposib vlovlyuvannya vysokodyspersnoyi kraplynnoyi ridyny z hazoridynnoho potoku [The method of capturing highly dispersed dropped liquid from the gas-liquid flow]. Certificate of the authorship, Ukraine, No. 102445 U, B01D 45/04 (2006.01). Sumy, Sumy State University, No. u201505124, bulletin No. 20 [in Ukrainian]. 3. Liaposhchenko, O. O., Nastenko, M. M., Pavlenko, I. V., et al. (2016). Sposib vlovlyuvannya vysokodyspersnoyi kraplynnoyi ridyny z hazoridynnoho potoku [The method of capturing highly dispersed dropped liquid from the gas-liquid flow]. Certificate of the authorship, Ukraine, No. 111039 U, B01D 45/00 (2006.01). Sumy, Sumy State University, No. u201605061, bulletin No. 20 [in Ukrainian]. 4. Sloboda, O., Korba, P., Hovanec, M., & Pila, J. (2016). Numerical approach in aeroelasticity. Scientific Journal of Silesian University of Technology. Series Transport, Vol. 93, 115–122. DOI: https://doi.org/10.20858/sjsutst.2016.93.12. 5. Afanasyeva, I. N., & Lantsova I. Yu. (2017). Numerical simulation of an elastic structure behavior under transient fluid flow excitation. Investigation of aerodynamic instability of a thin plate. MATEC Web of Conferences, Vol. 117, article No. 00099. 6. Zahed, P., Zhang, J.; Arabnejad, H., McLaury, B. S., & Shirazi, S. A. (2017). CFD simulation of multiphase flows and erosion predictions under annular flow and low liquid loading conditions. WEAR, Issue 376, 1260–1270. DOI: https://doi.org/10.1016/j.wear.2017.01.111. 7. Yao, J., Yao, Y. F., Arini, A., Mciiwain, S., & Gordon, T. (2016). Modelling air and water two-phase annular flow in a small horizontal pipe. Proceedings of the sixth international symposium on physics of fluids (ISPF6). International Journal of Modern Physics-Conference Series, Issue 42. DOI: https://doi.org/10.1142/S2010194516601587.

Journal of Engineering Sciences, Volume 4, Issue 2 (2017), pp. B 19–B 24

B 23

8. Liaposhchenko, О., Nastenko, O., Pavlenko, I. (2017). The model of crossed movement and gas-liquid flow interaction with captured liquid film in the inertial-filtering separation channels. Separation and Purification Technology, Vol. 173, 240–243. DOI: 10.1016/j.seppur.2016.08.042 9. Nastenko, O., Liaposhchenko, O., et al. (2016). Mathematical modelling of separation process by coupled heat transfer in the inertial-filtering gas separator-condenser. Inżynieria i Aparatura Chemiczna, No. 2, 62–63. 10. Karintsev, I. B., & Pavlenko, I. V. (2017). Hydroaeroelasticity: a textbook. Sumy, Sumy State University. 11. Brittle, S., Desai, P., Ng, W. C., Dunbar, A., Howell, R., Tesar, & Zimmerman, W. B. (2015). Minimising microbubble size through oscillation frequency control. Chemical engineering research & design, Issue 104, 357–366. DOI: https://doi.org/10.1016/j.cherd.2015.08.002. 12. Wu, Y. R., & Wang, C. H. (2017). Theoretical analysis of interaction between a particle and an oscillating bubble driven by ultrasound waves in liquid. Chinese physics B, Volume 11, Issue 26, No. 114303. DOI: https://doi.org/10.1088/16741056/26/11/114303. 13. Go, D. B., Atashbar, M. Z., Ramshani, Z., & Chang, H. C. (2017). Surface acoustic wave devices for chemical sensing and microfluidics: a review and perspective. Analytical methods, Volume 28, Issue 9, 4112–4134. DOI: https://doi.org/10.1039/c7ay00690j. 14. Pavlenko, I. V. (2006). Finite element method for the problems of strength of materials and linear theory of elasticity. Sumy : Sumy State University [in Russian]. 15. Liaposhchenko, O. O., Demianenko, M. M., Lytvynenko, O. V., Ivanov V. O., Ostroga, R. O., Lytvynenko, A. V., Pavlenko, I. V., & Dehriarov, I. M. (2017). Development and implementation of energy efficient modular separation devices for oil and gas purification equipment. Sumy, Sumy State University, No. 15.01.06-01.17/20.ZP, 2017-2020, State Reg. No. 0117U003931.

B 24

Investigation of Operating Processes in Machines and Devices

JOURNAL OF ENGINEERING SCIENCES УРНА ІН

Н РНИХ НАУ УРНА ИН

Н РНЫХ НАУ Web site: http://jes.sumdu.edu.ua

DOI: 10.21272/jes.2017.4(2).f1

Volume 4, Issue 2 (2017) UDC 544.032.4

Formation of hydroxyapatite coatings with addition of chitosan from aqueous solutions by thermal substrate method Yanovska G. O.1, Bolshanina S. B.1*, Kuznetsov V. M.2 1

Sumy State University, 2 Rymskogo-Korsakova St., 40007, Sumy, Ukraine; Institute of Applied Chemistry of the National Academy of Sciences of Ukraine, 3 Rymskogo-Korsakova St., 40007, Sumy, Ukraine

Article info: Paper received: The final version of the paper received: Paper accepted online:

Corresponding Author’s Address:

September 27, 2017 December 1, 2017 December 3, 2017

svet.bolshanina@gmail.com

Abstract. The aim of this investigation was obtaining of biocompatible coatings for medical implants based on biopolymer chitosan and hydroxyapatite, which is the main mineral component of bone tissue. Coatings were obtained by thermal substrate method, because it allows low temperature deposition and provides possibility to incorporate into coating structure biomolecules, unstable at high temperatures. As a way of chitosan incorporation into coating composition co-precipitation method was proposed. It allows obtaining uniform coatings with required composition and morphology. The obtained coatings were investigated by using of XRD, SEM with EDS, adhesion was tested by test-tape method. It was assigned that chitosan addition decreased hydroxyapatite crystallinity, so the range of concentrations from 0.01 to 0.1 g/L was chosen at pH = 6.5. It was determined that variation of chitosan concentrations in the initial solution influenced on morphology and structure of hydroxyapatite coatings as well as on the antibacterial properties and the use in orthopedics and dentistry. The best characteristics were obtained for hydroxyapatite-chitosan coatings deposited from solution with chitosan concentration 0.025 g/L.

Keywords: hydroxyapatite, chitosan, coating, deposition, thermal substrate method.

1 Introduction Metal ion release of medical implants lead to inflammatory effects in the physiological environment. That’s why the application of bioactive coatings for implant materials is a very promising way to solve this problem. Chitosan (CS) and hydroxyapatite (HA) are among the best bioactive biomaterials in bone tissue engineering due to their excellent biocompatibility in the physiological environment [1]. Hydroxyapatite, Ca10(PO4)6(OH)2, is widely used in dentistry and orthopedics. It is one of the most thermodynamically stable forms of calcium phosphate which occurs in the bone as a major component (from 60 to 65 %) [2]. Chitosan is an alternative polymer for use in orthopedic applications due to its good biocompatibility, biodegradability, porous structure, suitability for cell growth, osteoconduction and intrinsic antibacterial nature [3–5]. Chitosan is an N-deacetylation product of chitin. It is a copolymer consisting of β-(1→4)-2acetamido-d-glucose and β-(1→4)-2-amino-D-glucose

unit linkages [6–7]. It has good solubility in various organic acid solutions and sufficient resistance in alkali environments. In addition, chitosan is flexible and has a high resistance upon heating due to the intermolecular hydrogen bonds formed between hydroxyl and amino groups [8–10]. When chitosan is dissolved in a diluted organic acid solution, its free amino groups are protonated, although it is insoluble in an aqueous solution at pH > 7 [11]. Several methods are available for the application of HA coatings onto metal substrates [12]. But only few of them are acceptable for obtaining CS-HA coatings, because of high temperatures of processes and possibility of chitosan degradation. Among methods for HA-CS coating deposition are simple mixing and heating method [13], biomimetic method [14-16], low temperature wet chemical method [17], electrochemical deposition [18], electrochemistry assisted deposition [19, 20], electrophoretic deposition [21, 22]. In our work we proposed thermal substrate method [23, 24] (TSM) for deposition of

Journal of Engineering Sciences, Volume 4, Issue 2 (2017), pp. F 1–F 4

HA-CS coatings onto Ti6Al4V substrates from aqueous solutions. The main advantage of this method is a thermal activation near substrate surface which immersed in aqueous solutions containing Ca2+ and PO43– for hydroxyapatite synthesis with promoted crystallization and formation of film-like deposits [24]. Several factors influence the HA nucleation and crystallization: chitosan concentration in the initial solution, pH value of the solution, Ca2+ and PO43– ion concentrations, the heating time and temperature, substrate surface modification, etc. At the present work an attempt has been made for the first time HA-CS coatings deposition onto Ti6Al4V substrates by TSM. The aim of our study was to compare various concentrations of chitosan inserted into hydroxyapatite coatings. The main characteristics of obtained coatings were investigated and compared. The influence of chitosan onto calcium-phosphate formation during deposition was also studied.

2 Experimental 2.1

Materials

Ti6Al4V specimens, 36×1.9×0.36 mm in size, were used as substrates for HA-CS coatings deposition. They were polished with sandpaper, washed in acetone (15 min), 96 % ethanol (15 min) and three times rinsed with distilled water under ultrasound. Biomedical grade chitosan (200 kDa molecular weight) was supplied by the Haidebei Marine Bio Ltd. (Jinan, China) with 91 % degree of the deacetylation. Solutions with various chitosan concentrations were prepared by dissolving the 1 g of chitosan fibers in 1 liter of 1 % CH3COOH solution with vigorous stirring. Chitosan solution with concentration 1 g/l was diluted to required CS concentrations: 0.01, 0.025, 0.05, and 0.1 g/l by mixing with the initial solution for HA synthesis which contains CaCl2 (10 mmol/dm3) and NaH2PO4 (6 mmol/dm3).

2.2

Obtaining of HA-CS coating by thermal substrate method

Chitosan was inserted into hydroxyapatite coatings by co-deposition of hydroxyapatite and chitosan. The initial solution for coating deposition was prepared by mixing solution which contains CaCl2 (10 mmol/dm3) and NaH2PO4 (6 mmol/dm3) with chitosan solution (1 g/l) in various proportions (Table 1). The thermal substrate method for obtaining of HA coatings based on the main principle that the solubility of HA in aqueous solutions decreases with increasing substrate temperature [2, 24]. Alternating current passed through the system to heat the substrate. By this method hydroxyapatite directly coated the substrate without precipitation in the initial solution. The experimental arrangement for coating deposition is described in the work [24]. Co-deposition of hydroxyapatite coatings was carried by TSM method under following conditions: substrate temperature 100–105 ºC, pH of the initial solution 6.5– 6.85, time of deposition – 180 min.

Materials Science

Table 1 – The composition of the initial solution for codeposition of HA-CS coatings, ml Volume of reagents Chitosan solution in 1 % CH3COOH (1 g/l) CaCl2 (10 mmol/dm3)/ NaH2PO4 (6 mmol/dm3)

2.3

Chitosan concentration (g/l) 0.001 0.025 0.05 0.1

Without chitosan

–

198

195

190

180

200

Analysis techniques

The crystallinity and structure of the coatings were examined using an X-ray diffractometer DRON 4-07 (“Burevestnik”, Russia) connected to a computer-aided system for the experiment control and data processing. The Ni-filtered CuKα radiation (wavelength 0.154 nm) with a conventional Bragg–Brentano  -2 geometry was used. The current and the voltage of the X-ray tube were 20 mA and 40 kV, respectively. The samples were measured in the continuous mode at a rate of 1.0 deg/min, with 2θ-angles ranging from 15° to 55°. All experimental data were processed by means of the program package DIFWIN-1 (“Etalon PTC” Ltd, Russia). Identification of crystal phases was done using a JCPDS card catalog (Joint Committee on Powder Diffraction Standards. The surface morphology of HA-CS coatings was examined by Scanning electron microscopy (SEM). These investigations were performed in combination with X-ray emission spectroscopy using the REMMA-102 device (SELMI, Sumy, Ukraine). The surface chemical composition was determined with an energy dispersive X-ray (EDX) detector. The analytical signal of the characteristic X-ray emission was integrated by scanning the 50×50 m2 area of the sample surface. Adhesion of obtained coatings was measured by tapetest method as described elsewhere [25].

3 Results and discussion Chitosan dissolution in acetic acid described as follows: CS–NH2 + HOOC–CH3 → CS–NH3+ + CH3COO– (1) Viala et al. (26) established that the presence of calcium and phosphate ions in the solution allows the soluble form of CS to exist when below pH 6.7. At pH 6.65-7.0 calcium and phosphate ions existed in the initial solution and deposited on the substrate. Simultaneously, the following reaction of hydroxyapatite formation takes place on the substrate surface: 10Ca2++ H2PO4–+14OH–→Ca10(PO4)6(OH)2+12H2O(2) Morphology of the CS-HA coatings obtained by TSM method from solutions with chitosan concentrations 0.001–0.1 g/l is shown in Fig. 1.

Figure 1 – Morphology of the HA-CS coatings co-deposited by TSM method from aqueous solutions with chitosan concentrations 0.1 g/l (A), 0.05 g/l (B), 0.025 g/l (C), 0.001 g/l (D)

As can be seen in Fig.1 the most uniform coatings with rough surface were obtained from solutions with chitosan concentrations 0.001−0.025 g/l. It could be due to the possible interaction of chitosan macromolecules with components of initial solution. From the XRD-spectra (Fig. 2) it could be seen that with increasing of chitosan concentration in the initial solution for HA synthesis the relation of intensities of the main HA peak (2θ = 31,65°) to diffusive peak of chitosan (2θ = 20º) are decreased.

When chitosan is dissolved in acetic acid its amino groups are protonated (CS−NH3+) and bonds with carboxyl groups (CH3COO−) presented in solution. If other ions Ca2+, HPO4− are also presented in the initial solution some positively charged complexes for example CH3COO−−Ca2+ and HPO4−−Ca2+ can be formed in the solution. Such complexes adsorbed negatively charged PO43− with following crystal growth of HA. The presence of Ca2+ ions in the initial solution leads to chemical interaction between the calcium ions on HA surface and the amino groups in a chitosan molecule. In general, chitosan forms a chitosan–metal complex in which the metal ion coordinates the amino group in chitosan molecules [26]. Activity of the Ca2+ ions is somewhat weaker than that of the transition metal ions [11]. We suggest that small HA crystallites are able to align along the chitosan molecule upon aggregation through the interaction between the Ca2+ ions on the HA surface and the amino groups of the chitosan molecule. In other words, the c-axes of HA nano-crystals are parallel to the chitosan molecules due to formation of complexes of Ca2+ and amino groups of chitosan, which are the nucleation centers for HA crystals [11]. Measured adhesion strength of obtained HA-CS coatings is presented in the Table 2. Table 2 – Adhesion strength of HA-CS coatings obtained from solutions with various CS concentrations Adhesion strength/ composition N/m2 МPa

HA/CS coatings obtained from solutions with CS concentration (g/L) 0.025 0.05 0.1 2·105 66670 54540 0.2 0.07 0.05

HA 8·104 0.08

So the most adhesive strength was observed for HACS coatings with CS concentration 0.025 g/L. The obtained coatings due to the existence of CS could reveal antibacterial properties and find its application in dentistry or orthopedics.

4 Conclusions

Figure 2 – X-ray diffraction patterns of HA-CS coatings obtained by TSM from aqueous solutions with chitosan concentrations 0.1 g/l (A), 0.05 g/l (B), 0.025 g/l (C), 0.001 g/l (D)

Novel HA-CS composite coatings were obtained by co-deposition from aqueous solutions having chitosan concentrations (0.001–0.1 g/l) using thermal substrate method. This method is very perspective in comparison with other methods of coatings deposition, because it gives possibility to obtain coatings under temperatures from 40 to 120ºC. Due to the low temperatures of deposition polymer addition and composite coating formation is possible. The obtained HA-CS coatings have developed surface that could improve osteointegration. Concentration of CS 0.025 g/L allows obtaining HA-CS coating with adhesion strength 0.2 MPa.

Journal of Engineering Sciences, Volume 4, Issue 2 (2017), pp. F 1–F 4

References

1. Wang, M. (2003). Developing bioactive composite materials for tissue replacement. Biomaterials, Vol. 24, 2133–2151. 2. Elliott, J. C. (1994). Structure and chemistry of the apatites and other calcium orthophosphates. Elsevier. London, pp. 111–127. 3. Vande V. P. J., Matthew, H. W. T., et al. (2002). Evalution of the biocompatibility of chitosan scaffold. J. Biomed. Mater. Res., Vol. 59, 585–90. 4. Eugene, K., & Lee, Y. L. (2003). Implantable application of chitin and chitosan. Biomaterials, Vol. 24, 2339–2349. 5. Di Martino, A., Sittinger, M., & Risbud, M. V. (2005). Chitosan: A versatile biopolymer for orthopedic tissue-engineering. Biomaterials, Vol. 26, 5983–5990. 6. Je, J., & Kim, S. (2005). Water soluble chitosan derivatives as a BACE1 inhibitor. Bioorg. Med. Chem., Vol. 13, 6551–6555. 7. Jeon, Y., Shahidi, F., & Kim, S. (2000). Preparation of chitin and chitosan oligomers and their applications in physiological functional foods. Food Rev. Int., Vol. 16, 159–176. 8. Okuyama, K., Noguchi, K, et al. (1999). Structural study of anhydrous tendon chitosan obtained via chitosan/acetic acid complex. Int. J. Biol. Macromol., Vol. 26, 285–293. 9. Ogawa, K., Hirano, S., et al. (1984). A new polymorph of chitosan. Macromolecules, Vol. 17, 973–975. 10. Lee, Y. L., Khor, E., & Ling, C. E. (1999). Effects of dry heat and saturated steam on the physical properties of chitosan. J. Biomed. Mater. Res., Appl. Biomater., Vol. 48, 111–116. 11. Yamaguchi, K., Tokuchi, H., et al. (2001). Preparation and microstructure analysis of chitosan/hydroxyapatite nanocomposites. J. Biomed. Mater. Res., Vol. 55, 20–27. 12. Venkatesan, J., & Kim, S.-K. (2010). Review. Chitosan composites for bone tissue engineering – An overview. Mar. Drugs, Vol. 8, 2252–2266. 13. Ding, S. (2007). Biodegradation behavior of chitosan/calcium phosphate composites. J. Non-Cryst. Solids, Vol. 353, 2367–2373. 14. Li, Q., Chen, Z., et al. (2006). Biomimetic synthesis of the composites of hydroxyapatite and chitosan–phosphorylated chitosan polyelectrolyte complex. Mater. Lett., Vol. 60, 3533–3536. 15. Verma, D., Katti, K., & Katti, D. (2008). Effect of biopolymers on structure of hydroxyapatite and interfacial interactions in biomimetically synthesized hydroxyapatite/biopolymer nanocomposites. Ann. Biomed. Eng. Vol. 36, 1024–1032. 16. Davidenko, N., Carrodeguas, R., et al. (2010). Chitosan/apatite composite beads prepared by in situ generation of apatite or Siapatite nanocrystals. Acta Biomater., Vol. 6, 466–476. 17. Murugan, R., & Ramakrishna, S. (2004). Bioresorbable composite bone paste using polysaccharide based nano hydroxyapatite. Biomaterials, Vol. 25, 3829–3835. 18. Redepenning, J., Venkataraman, G., Chen, J., & Stafford, N. (2003). Electrochemical preparation of chitosan/hydroxyapatite composite coatings on titanium substrates. J. Biomed. Mater. Res., Vol. 66, 411–416. 19. Pang, X., & Zhitomirsky, I. (2005). Electrodeposition of composite hydroxyapatite–chitosan films. Mater. Chem. Phys., Vol. 94, 245–251. 20. Huang, Z., Dong, Y., Chu, C., & Lin P. (2008). Electrochemistry assisted reacting deposition of hydroxyapatite in porous chitosan scaffolds. Mater. Lett., Vol. 62, 3376–3378. 21. Pang, X., Casagrande, T., & Zhitomirsky, I. (2009). Electrophoretic deposition of hydroxyapatite-CaSiO3-chitosan composite coatings. J. Colloid Interface Sci., Vol. 330, 323–329. 22. Pang, X., & Zhitomirsky, I. (2007). Electrophoretic deposition of composite hydroxyapatite-chitosan coatings. Mater. Charact., Vol. 58, 339–348. 23. Sukhodub, L. B., Moseke, C., et al. (2003). Improved thermal substrate method with cooling system for hydroxyapatite coatings on titanium substrates. Annual Report. Institut für Kernphysik. Westfalishe Wilhelmsuniversität Münster, pp. 86–88. 24. Yanovska, A., Kuznetsov, V., et al. (2011). Synthesis and characterization of hydroxyapatite-based coatings for medical implants obtained on chemically modified Ti6Al4V substrates. J. Surf. Coat. Technol., Vol. 205, 5324-5329. 25. Horkavcová, D., Plešingerová, B., et al. (2008). Adhesion of the bioactive layer on titanium alloy substrate by Tape-test. Ceramics. Silikáty, Vol. 52, No. 3, 130–138. 26. Viala, S., Freche, M., & Lacout J. L. (1998). Preparation of a new organic-mineral composite: chitosan-hydroxyapatite. Ann. Chim. Sci. Mater., Vol. 23, Issues 1–2, 69–72.

Materials Science

JOURNAL OF ENGINEERING SCIENCES УРНА ІН

Н РНИХ НАУ УРНА ИН

Н РНЫХ НАУ Web site: http://jes.sumdu.edu.ua

DOI: 10.21272/jes.2017.4(2).f5

Volume 4, Issue 2 (2017) UDC 669-178

Influence effect of electric action on the micro structure of steel in crystallization Zhbanova O. M.* State Higher Educational Institution “Kryvyi Rih National University” Article info: Paper received: The final version of the paper received: Paper accepted online:

Corresponding Author’s Address:

October 10, 2017 December 1, 2017 December 4, 2017

zhbanova.olena@gmail.com

Abstract. The dependence of physical and mechanical properties of manganese steel grade 110H13L on the effect of electrical activity during crystallization of the casting is considered. Treatment of the melt by electric current increases the speed of dissolution of metallic impurities and other components in the melt many times, providing not only finely crystalline structure, but also improving the homogeneity of metal casting. Improvement of mechanical properties is a consequence of crushing those which constitute microstructure. Processing by electric current does a beneficial effect on the process of crystallization of metal melts during casting, which significantly improves the structure of the ingot and its mechanical properties. Keywords: steel, microstructure, electrical processing, mechanical properties, crystallization.

F 1 Introduction In the production of hadfield steel [1] it is required to solve a number of points that affect both the technological, casting and performance properties of castings: ─ while operating on 110H13L steel under conditions of high abrasive and low dynamic loads, there is not enough time for a hardened surface layer to be formed, which leads to short life of the system components; ─ high content of phosphorus, introduced in steel with medium-and high-carbon ferromanganese, and as a consequence – phosphide eutectic on the borders of grain; ─ carbides on the borders of grain; ─ high content of gases and non-metallic inclusions in the metal and high nitrous manganese in the slag; e) tendency to dendrite growth at high temperature casting. Urgent task for metallurgical enterprises today is metal processing aimed at improvement of its physical properties. One of the promising methods of influencing the structure and properties of casting alloys is the melt processing by electric current during crystallization. Electrical material processing is an independent area for oriented control of metal properties which is rapidly developing [2]. Application of electric and magnetic fields over liq-

uid metal that crystallizes, allows you to effectively control the movement of the melt, heat and mass transfer processes, as well as the structure and properties of castings [3]. It is known that the motion of ions in the liquid alloy is chaotic. Directional diffusion of ions can be created by changing their concentration gradient in the melt which is achieved either by changing of partial pressure over the metal, or by directed movement of non-metallic inclusions while being absorbed by fluxes in as a result of some effect upon liquid metal caused by the direct current, for instance.

2 Statement of the problem Processing of liquid melt by electric current creates conditions for directional solidification in the interelectrode space which allows managing the process of crystallization of castings. Mechanisms of action of the direct current are based on the onset and development, Peltier effect in liquid and solid phase used in the zoned melting [4]. At the same time, the current, being an internal source of energy, additionally heats castings, stabilizing the temperature field in time and in its bulk. Therefore, the use of the current in the process of casting reduces the likelihood of calamity in the form of metal, which is especially important in obtaining thin cast products.

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Earlier studies have been conducted on the impact of electrical activity on the crystallization of copper and aluminium. In order to improve the performance properties of wear-resistant steel, reduce energy and material consumption within the process, a complex study on the application of electrical activity is required.

3 Results and discussion a

The technology for experimental batch of castings out of 110H13L metal alloy, that includes treatment by electric current in the process of crystallization, was tested in the foundry of LLC “Zodchiyi”. In order to ensure that the chemical composition of the obtained alloys complies with the requirements of GOST 1583-93, the charge was calculated, and additives were previously split and weighed. Experimental melting was performed in an induction furnace. Temperature control was carried out by platinum-rhodium thermocouple, which is a part of the measuring complex as a primary sensor. Pouring of testing samples was carried out at the temperature of 1490 °C into a sand mold by the method of casting into consumable patterns. In this work we investigated the effect of direct electric current on the crystallization and properties of casting alloys. Melt processing by electric current in the process of crystallization was carried out by using the device. The device contains a 200 A shunt, a direct current amperemeter ranging from 0 to 200 A, a direct current voltmeter ranging from 0 to 50 V, 200–300 A diodes and conductive elements 1, summed up to electrodes. Processing of castings by electric current was conducted at the beginning of pouring metal into pattern before the end of crystallization. We applied direct current with voltage of 25-55V and density of 4.5 A/cm2. Analysis of microstructure of the obtained alloy samples revealed that electrical current commits modifying effect upon crystallization of the metal. Primary grain metal base gets crushed (Fig. 1). When processing castings by electric current the quantity of non-metallic inclusion decreases 1.4-2.5 times. The alloy processed by electric current, has better casting technological properties, it has a better ability to fulfil the pattern and crystallizes with less shrinkage. Processing by electric current regulates the size and quantity of separate structural components of alloys, and results in grain refinement (Fig. 2) Effects of electric current of high density on crystallization can reversibly alter the amount of solid and liquid phases. The current, warming up local regions and microvolumes of the material, ensures its transition from solid to liquid state. This makes it possible to regulate time of transition from liquid to solid state, i.e. support existence of the aggregate state of the material. As a result of experimental casting forms two samples were obtained. One uses electric influence and the other without. The effect of electrical stimulation influences on the formation of the crystalline structure and on the development of shrinkage defects. It was found that castings produced without the use of electrical stimulation is open

Materials Science

Figure 1 – Microstructure of alloy 110H13L×50: a – initial alloy; b – alloy processed by electric current

Figure 2 – Microstructure of alloy 110H13L×300: a – initial alloy; b – alloy processed by electric current

shrinkage cavities; in which the casting under the electrical influence is not pronounced shrinkage sink. In addition, after the study of the internal volume of the treated casting is absent. When processing, castings electric current amount of non-metallic inclusions decreased 1.42 times. Microanalysis samples showed that the metal structure of the cross section of the same test samples and consists of austenite, perlite and carbides evolved both inside and the grain boundary carbides, predominantly acicular form. The electrical influence contributes grinding grain. The hardness of the metal in the casting obtained without electrical stimulation is 242 HB, in the sample after the application of electrostimulation increased by 12.4 % and reached 272 HB.

4 Conclusions Treatment of the melt by electric current increases the speed of dissolution of metallic impurities and other components in the melt many times, providing not only finely crystalline structure, but also improving the homogeneity of metal casting. Tensile strength increased by 10–20 %. Improvement of mechanical properties is a consequence of crushing those which constitute microstructure. Processing by electric current does a beneficial effect on the process of crystallization of metal melts during casting, which significantly improves the structure of the ingot and its mechanical properties.

References 1. Ivanov, A. V., Sinchuk, A. V., & Tsurkin V. N. (2011). Elektrotokovaya obrabotka zhidkih i kristallizuyuschihsya splavov v liteynyih tehnologiyah [Electro-current treatment of liquid and crystallizing alloys in foundry technologies]. Elektronnaya obrabotka materialov. Vol. 47, No. 5, 89–98 [in Russian]. 2. Kischenko, O. M., & Tkach, V. V. (2012). Suchasni metodi regulyuvannya protsesu kristalizatsiyi livarnih splaviv [Modern methods of regulation of the process of crystallization of foundry alloys]. Visnik KrivorIzkogo natsIonalnogo universitetu, No. 30, 221–223 [in Ukrainian]. 3. Minenko, G. N. (2006). Ob energeticheskom vozdeystvii na metallicheskiy rasplav [On the energy impact on a metallic melt]. Metallurgiya mashinostroeniya, No. 3, 10–12 [in Russian] 4. Tkach, V. V., & Kischenko, E. N. (2015). Vliyanie elektrovozdeystviya v protsesse kristallizatsii na svoystva stali 110G13L [Effect of electrostatic action in the process of crystallization on the properties of 110G13L steel]. Elektrometallurgiya, No. 7, 9–11 [in Russian].

Journal of Engineering Sciences, Volume 4, Issue 2 (2017), pp. F 5–F 7

JOURNAL OF ENGINEERING SCIENCES УРНА ІН

Н РНИХ НАУ УРНА ИН

Н РНЫХ НАУ Web site: http://jes.sumdu.edu.ua

DOI: 10.21272/jes.2017.4(2).f8

Volume 4, Issue 2 (2017) UDC 669.71-034.7:539.2/.6:629.33:338.5

Modern materials for automotive industry Hovorun T. P., Berladir K. V.*, Pererva V. I., Rudenko S. G., Martynov A. I. Sumy State University, 2 Rymskogo-Korsakova St., 40007, Sumy, Ukraine Article info: Paper received: The final version of the paper received: Paper accepted online:

Corresponding Author’s Address:

September 30, 2017 December 2, 2017 December 4, 2017

kr.berladir@pmtkm.sumdu.edu.ua

Abstract. The car industry uses a tremendous number of materials to build cars, including iron, aluminum, steel, glass, rubber, petroleum products, copper, steel and others. These materials have evolved greatly over the decades, becoming more sophisticated, better built, and safer. They've changed as new automotive manufacturing technologies have emerged over the years, and they're used in increasingly innovative ways. This article is devoted to systematization information on the introduction and application of modern materials in the automotive industry. Given both domestic and foreign sources of information, it follows that car manufacturers are constantly pushing to create the lightest cars possible to increase speed and power. Research and development into lightweight materials is essential for lowering their cost, increasing their ability to be recycled, enabling their integration into vehicles, and maximizing their fuel economy benefits. Light weighting without loss of strength and speed properties is the present, and the future, of the automotive manufacturing industry. It brings innovative materials to the frontline of design. Keywords: steel, aluminum, aluminum alloys, aluminum matrix composites, polymer and composite materials, plastics, lightweight materials.

1 Introduction Automotive is one of the largest consumers of construction materials in the world [1]. Increasing the durability and reliability of the work of the parts of cars is a relevant and important problem of materials science. The development of the automotive industry, increasing the requirements for the quality and safety of used materials requires the creation and application of new forms. At the same time, the growth of resource requirements forms competition between manufacturers of different materials stimulates progress in developing their new types and improving quality [2–4]. The automotive industry employs the latest innovative developments that emerge from the development of science and new technologies. Among the main vectors in the modern automotive industry are: ─ creation of intelligent cars that can handle various difficult situations on the road without driver involvement; ─ development of cars with alternative energy sources among them the most well-known and successful Tesla car line.

Materials Science

The performance of the cars is constantly improving, because the engines become more efficient, the body is more aerodynamic, the transmission is improved, the rolling resistance of tires is reduced. When creating a car, it is very important to reduce its mass. This allows maintaining the basic characteristics of the car, using less powerful engines that consume less fuel and emit less harmful substances into the atmosphere. In addition, the inertia of the car decreases and for its acceleration or breaking it is necessary to spend less energy. Lowering the weight of the car also reduces the load on the suspension parts, which increases their lifespan [5]. Lowering the weight of the car is due to the need to use new, lighter but rather durable materials that are usually more expensive, at the same time cars, for objective reasons, are becoming more complex and, accordingly, more difficult. New light construction materials should be offset by weight, including new units, and active and passive safety systems, reduced toxicity, and continuous improvement in comfort levels [6]. Lightweight constructions are increasingly used in automotive, aerospace and construction sectors, because using the low density materials allows reducing the structural weight of products. That may result in substantial fuel savings and a lower

carbon footprint in transportation and facilitates manipulation of details in the house construction applications [7]. Moreover, the low material density leads to conservation of natural resources, since less material is required for manufacturing consumer goods. More than half of the total volume in the production of a modern car consists of cast iron and steel parts(55 %), about 11 % – plastics, the third place – aluminium alloys (9 %); rubber and glass – 7 and 3 % respectively; the share of non-ferrous alloys (magnesium, titanium, copper and zinc) does not exceed 1 %; other materials (varnishes, paints, electric wires, facing materials, etc.) make 13.5 % (Fig. 1).

Figure 1 – Parts of various types of materials used for the manufacture of car parts

Traditionally, steel or various metal alloys are used to make all responsible parts of the car. Steel has high strength and reliability, but it is prone to corrosion, and the parts made of it, differ a fairly large mass [8]. Back in the 40th of the twentieth century, the first attempts were made to facilitate the design of the car through the use of parts made of synthetic fibers. Insufficiently worked out technology did not allow at that time to receive a material of high strength, therefore, from synthetic fibers originally manufactured only decorative panels of the car body. Today, thanks to the use of the latest advances in science, polymer compounds demonstrate much greater hardness and strength than conventional steel. Due to the interweaving of synthetic fibers, a strong reinforcing frame is formed by which the load is evenly distributed over the entire surface of the part. In addition, carbon fiber parts weigh almost three times less than steel-like strengths [9]. In the manufacture of elements of modern engines, materials on the basis of composite with an aluminium matrix are widely used [10]. They represent an alloy of aluminium, in which are added fibers of silicon and carbon, previously passed through a special matrix made of titanium or aluminium. Such technology allows in several times to increase the strength of the material for tension. The use of polymer materials can significantly reduce the cost of manufacturing automotive components [11].The details made of synthetic fibers by forming in the matrix, leave it fully ready for installation, without requiring additional processing and even colouring. From synthetic materials, it is not particularly difficult to make

parts of a very complex form, which would be very difficult to do with sheet steel. Polymer materials have virtually unlimited service life. They are not subject to corrosion; easily withstand the effects of significant loads and vibrations. The strength and stiffness of the car body elements made of synthetic fibers, can significantly improve the reliability and safety of the car while reducing its weight. The only obstacle to the widespread use of carbon fiber in automotive industry is the very high cost of its manufacture. A part made of synthetic fibers costs 30–40 times more expensive than a similar but made of steel. This leads to the fact that components from polymer materials are most often used in the manufacture of tuning cars of an individual assembly. However, over time, refinement of carbon fiber technologies will inevitably lead to a reduction in its value to the level of steel and light alloys. In connection with the above, the main direction of development of the automotive industry should be a significant increase in the quality of products using scientific and technical advances and the development of new materials to be used in the automotive industry. And this continues the development of the scientific direction of applied material science in the automotive industry. The purpose of this work is to systematize information on the introduction and application of modern materials in the automotive industry.

2 Steel construction materials for the manufacture of car parts Despite the increasing use of new construction materials in the automotive industry, steel production continues to play a leading role in the production of steel. On modern cars, most of the weight comes from steel. In 2007, for example, the average car contained 1 090 kg of steel, and the average pickup truck or SUV used nearly 1 360 kg [12]. The automobile industry is imposing very high demands on steel because, first of all, it must meet two diametrically opposite criteria. On the one hand, the requirement to reduce the mass of products involves the use of high-strength materials, on the other – the growth requirements for the production of technology involve the use of high-plastic materials [13]. Steel is the time-tested material. This material has been used in the manufacture of car bodies for a long time, thanks to its strength [13] (Fig. 2).

Figure 2 – Materials used for the manufacture of car bodies

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Requirements for materials for the manufacture of automobile bodies [14]: ─ high strength; ─ energy intensity (ability to absorb impact energy when collision); ─ manufacturability(the possibility of manufacturing parts of a complex form with a minimum number of operations); ─ minimum car body weight(the smaller the mass, the less the gas flow and the number of congenital emissions); ─ corrosion resistance; ─ maintainability. Steel manufacturing has evolved greatly, so carmakers these days can make different types of steel for different areas of the vehicle that are rigid or that can crumple to absorb different impacts [15]. The main parts of the car body are made of steel, aluminium alloys, plastics and glass. Moreover, the advantage is given to low-carbon sheet steel in the thickness of

Figure 3 – Advantages and disadvantages of using steel materials for automotive industry

(0.65–2) mm. Thanks to the latter, it managed to reduce the overall weight of the car and increase the rigidity of the body. The use of steel materials for cars has its advantages and disadvantages [13] (Fig. 3).Most car bodies, due to many reasons, are made of sheet steel. The most important of these reasons are: high strength, deformability (possibility of extraction), welding, coloring, sufficient service life with proper anticorrosion treatment, satisfactory cost (Table 1).

Table 1 – Types of sheet steel for car bodies

Steel

Type of steel

Thin sheet, cold-rolled killed

RRST 1405

Thin sheet, boiling steel

UST 1203, UST 1303

Hot-rolled steel tape

ST 4

Properties

Appoinment

the limit of strength 270–350 MPа, relative elongation is more than 36 %, thickness 0.6–0.9 mm the limit of strength 270–410 MPа, relative elongation 28–32 %, thickness 0.6-0.9 mm the limit of strength 280–380 MPa, relative elongation is more than 38 %, thickness 1.5-2.5 mm

The design and manufacturing technology of the parts should be guided by the maximum width of the supplied steel sheet (currently 2 000 mm).For parts working in a corrosive-aggressive environment, it is necessary to use galvanized sheet steel, given that in the manufacture of parts, such steel does not allow large decompositions (bend, a small exhaust).In special cases aluminum sheet steel can be used. Both surfaces of steel sheets can be specially treated. Material scientists are also working towards the development and application of ultra-highstrength alloys of the new generation [13] (Fig. 4).

specific external panels (roof, hood, door, sidewalls, etc.) painted external panels and floor parts (inner frame, amplifiers, floor panels, cross bars) for parts located beneath the car body (amplifiers, supports, flanges, etc.), especially large thickness

Figure 4 – Possibilities of application of ultra-high-strength alloys of new generation for details of the car

An example of using high-strength and especially high-strength steels in a car can serve as a model Audi Q5. The share of standard soft steels in the car body of this crossover is 31 % (made of especially stubborn components and external components that absorb energy when struck), high-strength – more than 44 % (almost the entire power frame protecting passengers), especially high-strength – almost 25 % (of which 9.1 % are ultrahigh strength steel of the new generation, which are used in the most responsible areas) [4]. Among the steels used in automobile construction, it is possible to note [4]: 1. Highly-plastic IF-steel, the structure of which is stabilized with micro-nutrients of titanium and/or niobium, and contains an extremely low carbon (≤ 0.005 %), which, together with nitrogen, is completely bound to carbides, nitrides and carbonitrides. 2. Steels, which are strengthened during the drying of paint and varnish coating (ВН-steel). The advantage of

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ВН-steels is the strengthening, which is achieved in a single technological flow during the drying of the paint and varnish coating of the car body. 3. Dual Phase (DP) steels with ferrite-martensitic (or ferrite-bainite) structure have high properties. «Soft» ferrite (up to 80 %) provides high plastic properties of DP-steels in its original state. 4. Transformation Induced Plasticity (TRIP) steels, the microstructure of which is a ferrite matrix with dispersion-distributed inclusions of a strong martensitic and/or bainitic component. 5. Complex Phase (CP) steels have a highly dispersed ferrite structure with a large volume fraction of solid phases (structural components). 6. Sheet steel containing 0.07 % , 0.6 % Si, 2.4 % Mn, has such typical properties of properties: σT = 710 N/mm2, σB = 1 010 N/mm2, δ5 = 14 %, δр = 8 %. 7. Martensitic (Mart) steels provide the value of the temporary resistance to 1 500 N/mm2. These were subjected to quenching with subsequent tempering to increase the plasticity and ensure high molding at very high deformation values.High-strength sheet steel is used mainly for rigidity elements. Details from such steels are made flexible in the stamps or roller machines, but such become prone to cracking and elastic return.In recent years, transition to more high-tech processes – hot sheet punching with hardening in the die. 8. Each year, the use of high-strength steels of the new generation such as AHSS (advanced high-strength steels) and UHSS (ultra high-strength steels) with the limit of fluidity of 400 to 1 200 N/mm2 increases. It should be borne in mind that their application requires not only significant changes in methods design details, but also stamping technology, the development of new technologies for the manufacture of parts and units (hydro-forming, profiling, laser welding of the body, etc.) [15]. Foreign experience shows that the steel of these types is expedient to use on automakers manufacturing components that affect the passive safety of the car (safety bars, spares, elements of the bumper system, etc.). 9. High-strength austenitic steels (σT ≥ 600 N/mm2) (Twinning Induced Plasticity – TWIP steels), which have very high plastic properties (full elongation of more than 80 %), are actively developed. The unique properties of these high-manganese (up to 30 % Mn) steels containing up to 9 % aluminum are provided by double-crystalline lattice. Low energy of packing defects combined with reinforcing deformation martensitic transformations allows to effectively strengthen these steels when hydro-pressing. 10. High-strength and super-plastic steels of a new generation for lightweight structures (TRIPLEX-steels) on the basis of a four-component system Fe-Mn-Al-C with an aluminum content of up to 12 % are characterized by a lower specific mass (up to 14 %), high limit of fluidity (800–1 000 N/mm2) increased relative elongation (up to 70 %) and excellent ability to deep extract. The structure of steel consists of austenitic ma-

trix, volumetric ferrite particles and nano-dispersed particles of carbides. This is achieved by thermal treatment with a controlled and even distribution of k-carbides, which results in a precision uniform displacement of the crystal lattice. This leads to extremely high formability. This mechanism is designated as SIP-effect (shear band induced plasticity). 11. Nano-structured hot-rolled steel NANOHITEN (development by the company JFE Steel) with high limit of fluidity (780 N/mm2) is based on ferrite structure, strengthened with dispersed particles. Such a microstructure provides a high value of relative elongation (up to 25 %). Since NANOHITEN steel does not contain silicon, it is well exposed to hot zinc and is already used in body structures and safety components, as well as for levers, brackets and chassis parts. Perspectives of the development of steel materials for automotive industry are shown in Figure 5.

F Figure 5 – Perspectives for the development of steel materials for automotive industry

3 Results and discussion 3.1

Aluminum alloys and composites with an aluminum matrix for automotive industry in order to reduce the weight of cars

Aluminum alloys for the manufacture of car bodies began to be used relatively recently [17]. But this metal has already gained popularity among automakers, because it is lightweight and virtually non-corrosive. With the use of aluminum alloys are made both body and some parts of the suspension and engine. The disadvantage of using aluminum is a laborious process of welding components and high conductivity vibration and noise. To reduce vibration and noise, manufacturers use silent insulation, which ultimately affects the price of the car [13] (Fig. 6). Aluminum car bodies have already reached the level of mass production, although only on expensive models. Many parts of the chassis have been mastered from aluminum instead of steel, as well as lighter components. But the struggle with the weight of the car continues and goes to a new level in connection with the rigor of demands for efficiency and environmental friendliness.

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Figure 6 – Advantages and disadvantages of using aluminum for automotive industry

Aluminium in this struggle, of course, is still a leading place, since there are also more attractive materials with high mechanical properties, but even more light. Mastering them in mass production are leading automotive firms and component manufacturers [4]. Audi Company uses new aluminum in its production, which affects the price. But not all manufacturers can completely switch to aluminum car bodies, so they have to combine aluminum with steel to make the car cheaper. Concern BMW manufactures some series of cars with this technology.For example, in the fifth series the front part of the car body is made entirely of aluminum alloy and welded with a steel frame. The use of aluminum and its alloys for the manufacture of car bodies is practiced by automobile manufacturerssuch as Rover, Jaguar, Audi and BMW. Thanks to aluminum, the car gets much easier; this affects the increase in speed, reducing CO2 and fuel consumption.This material is almost not subject to corrosion. Due to the excellent ductility metal effectively quenches impacts in case of an accident. But this same plasticity leads to the deformation of aluminum body parts, even when there are not very serious blows. Aluminum alloys are now used not only for the body of the car, but also for a number of parts of the steering knobs and suspensions. The physical and mechanical properties of this metal impose special requirements for the preparation and repair of aluminum parts. Low density of aluminum alloys, high machinability, ductility and fatigue strength; up to 30 % less, in comparison with cast iron, the coefficient of transmission from gas, as well as high thermal conductivity at the level 125– 146 W/m∙K made them the main piston materials of the present [18].

3.2

Aluminum alloys for automotive industry

The problem of improving the quality of aluminum alloys is relevant for all developed countries [19, 20]. The main tasks for the production of aluminum alloys used for automotive industry include the development of materials with the highest hardness, durability, corrosion resistance, plasticity and other physical and mechanical properties. To do this, various methods and techniques for improving these characteristics are used. One of the most important tasks is the purposeful management of the molded structure and properties of

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silumines in the bulk crystallization of castings in conventional non-stationary processes of traditional casting. The production and casting of aluminum alloys are widely used modification. Additives are introduced as a ligature in the charge or directly into the melt. Among the modifiers of the first kind of aluminum alloys are titanium and vanadium, which form refractory inter-metallic TiAl3 and VAl6, and ultrafine particles of oxides, carbides, borides and other nonmetallic inclusions. Modifiers second kind are surfactants which positively affect the structure of aluminum alloys, most of which are elements of group (Li, Na, K, Rb, Cs), and sulfur and phosphorus. At the same time, numerous studies have shown the high efficiency of complex modifiers [18]. Effective grinding of grain of aluminum alloys is possible due to the adding of fine-dispersed aluminumtitanium-boron (AlTiB) and aluminum-titanium-carbon (AlTiC) crystals in the melt of various compositions that serve as crystallization centers. Adding this ligature results in improved mechanical properties and reduced gas porosity. The ligature is applicable to all aluminum alloys (pure aluminum, deformed alloys, and cast silumines. The authors [21] with the aim of improving the structure, mechanical and service properties, lower porosity, based on laboratory and pilot studies as a baseline for hypo-eutectoid silumins proposed a modifier containing elements which act as modifiers and second kind. The modifier included sulfur, sodium carbonate, ultrafine silicon carbide and electrolytic titanium. The results of research on the basis of the modifying complex allowed developing a number of highly effective refiningmodifying complexes for the processing of aluminum alloys obtained from low-grade raw materials [22–24]. Actual problem is the cheapening of raw materials of aluminum alloys by their recycling. The authors [18] have shown that the increase in the quality of silumins derived from 100 % of secondary raw materials to the level of primary, possibly due to the use of experimental refining-modifying complexes. The developed complexes have a low cost, do not complicate the technology of obtaining alloys, reduce the amount of harmful emissions into the environment and improve the sanitary standards in foundries, reduce the need for universal refiningmodifying preparations in 10–15 times. Due to the use of proposed modifiers, the possibility of using silumins for more stringent conditions of forced

work in knots and mechanisms of machines, especially for products of tribo-technical purposes, expands. Cast billet of silumines having sufficient level of plasticity (not less than 4–6 %), can be subjected to pressure treatment to enhance the properties and to ensure the accuracy of the shape of the product [25].

3.3

Aluminum matrix composites for the automotive industry

Aluminum matrix composites (AMCs) refer to the class of light weight high performance aluminum centric material systems. The reinforcement in AMCs could be in the form of continuous/discontinuous fibers, whisker or particulates, in volume fractions ranging from a few percent to 70 %. Properties of AMCs can be tailored to the demands of different industrial applications by suitable combinations of matrix, reinforcement and processing route [17, 26] ThemajoradvantagesofAMCscomparedtounreinforcedmaterialsareasfollows: greater strength, improved stiffness, reduced density (weight), improved high temperature properties, controlled thermal expansion coefficient, thermal/heat management, enhanced and tailored electrical performance, improved abrasion and wear resistance, control of mass (especially, in reciprocating applications) and improved damping capabilities [17]. AMCs can be classified into four types depending on the type of reinforcement [26] (Fig. 7).

or borides (Al2O3 or SiC or TiB2) and present in volume fraction less than 30% when used for structural and wear resistance applications [28–30]. In general, PAMCs are manufactured either by solid state (PM processing) or liquid state (stir casting, infiltration and in-situ) processes. PAMCs are less expensive compared to CFAMCs. Mechanical properties of PAMCs are inferior compared to whisker/short fiber/continuous fiber reinforced AMCs but far superior compared to unreinforced aluminium alloys. These composites are isotropic in nature andcan be subjected to a variety of secondary forming operations including extrusion, rolling and forging. Figure 8a shows the microstructure of cast aluminium matrix composite having high volume fraction (40 vol. %) SiC particle reinforcements [17]. Whisker or short fiber-reinforced AMCs (SFAMCs) contain reinforcements with an aspect ratio of greater than 5, but are not continuous. Short alumina fiber reinforced aluminium matrix composites is one of the first and most popular AMCs to be developed and used in pistons. These were produced by squeeze infiltration process. Figure 8 b shows the microstructure of short fiber reinforced AMCs. Whisker reinforced composites are produced by either by PM processing or by infiltration route [17]. Mechanical properties of whisker reinforced composites are superior compared to particle or

Figure 7 – Types of AMCs

Figure 8 – Microstructures of aluminum matrix composite having high volume fraction of SiC particle reinforcement (40 % vol.) (a), short fiber-reinforced aluminum matrix composite (b); continuous fiber-reinforced aluminum matrix composite (c); hybrid composite containing 10 % SiC and 4 % graphite particles (d)

Particulate Reinforced Aluminum Matrix Composites (PAMCs) are one of the key research and development areas of metal matrix composites. The development prospect is very broad and will lead the revolution of advanced materials through large-scale production and application [27]. These composites generally contain equated ceramic reinforcements with an aspect ratio less than about 5. Ceramic reinforcements are generally oxides or carbides

short fiber reinforced composites. However, in the recent years usage of whiskers as reinforcements in AMCs is fading due to perceived health hazards and, hence of late commercial exploitation of whisker reinforced composites has been very limited. Short fiber reinforced AMCs display characteristics in between that of continuous fiber and particle reinforced AMCs[31]. Continuous fiber-reinforced aluminum matrix composites (CFAMCs). Here, the reinforcements are in the form

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of continuous fibers (of alumina, SiC or carbon) with a diameter less than 20 m. The fibers can either be parallel or pre woven, braided prior to the production of the composite. AMCs having fiber volume fraction upto 40 % are produced by squeeze infiltration technique. More recently 3MTm corporation has developed 60 % vol. alumina fiber (continuous fiber) reinforced composite having a tensile strength and elastic stiffness of 1 500 MPa and 240 GPa respectively. These composites are produced by pressure infiltration route. Figure 8 c shows the microstructure of continuous fiber (alumina) reinforced AMCs [17]. Mono filament reinforced aluminium matrix composites (MFAMCs). Monofilaments are large diameter (from 100 to 150 m) fibers, usually produced by chemical vapour deposition (CVD) of either SiC or B into a core of carbon fiber or W wire. Bending flexibility of monofilaments is low compared to multifilament. Monofilament reinforced aluminium matrix composites are produced by diffusion bonding techniques, and is limited to super plastic forming aluminium alloy matrices. In CFAMCs and MFAMCs, the reinforcement is the principal loadbearing constituent, and role of the aluminium matrix is to bond the reinforcement and transfer and distribute load. These composites exhibit directionality. Low strength in the direction perpendicular tothe fiber orientation is characteristic of CFAMCs and MFAMCs. In particle and whisker reinforced AMCs, the matrix is the major load-bearing constituent. The role of the reinforcement is to strengthen and stiffen the composite by preventing matrix deformation by mechanical restraint. In addition to four types of AMCs described above, another variant of AMCs known as hybrid AMCs have been developed and are in use to some extent. Hybrid AMCs essentially contain more than one type of reinforcement. For example, mixture of particle and whisker, or mixture of fiber and particle or mixture of hard and soft reinforcements. Aluminium matrix composite containing mixture of carbon fiber and alumina particles used in cylindrical liner applications is an example of hybrid composite. Figure 8d shows microstructure of hybrid AMC having both hard SiC and soft graphite particles as reinforcement [17]. Their advantages are low density, specific strength, high specific stiffness, high shear strength, low thermal expansion coefficient, thermal stability and thermal conductivity, good electrical conductivity, wear resistance and resistance to organic liquids and solvent erosion.

Moreover, the abundant aluminium resources in the world, coupled with conventional equipment and process processing and processing, and thus the preparation and production of aluminium-based composite materials than other metal-based composite materials more economical, easy to promote and apply. Therefore, the PAMCs in the economic field have a wide range of applications, and have been generally attached [27]. Granular aluminium composite materials used in the car, can reduce the weight of the car and improve its performance, and can save oil, reduce pollution and extend the service life. Compared with cast iron, with A359 + 20 % vo1. SiC brake discs, weight reduction of 50 to 60 %, such as 5.4 kg weight cast iron plate with a composite material instead of weighing only 2.5 kg, after 5 000 km travel test shows that the composite brake disc wear less, and can reduce the brake noise and improve the thermal conductivity (cast iron is 5 to 7 times) [27]. Knorr Bremse AG developed a high-speed train brake disc for the German ICE-2 high-speed rail with a weight loss of 500 kg per unit using 20 % SiCp/AlSi7Mg composites manufactured by Duralcan. Kolbenschmidt developed 20-30% SiCp/Al-Si composite brakes for the Volkswagen Lupo – 3L TDI, similar brake discs for Toyota RAV – 4 EV cars, Plymouth prowler, Ford prodigy, Lotus Elise, etc. The Japan Toyota Motor Corporation manufactures 2 ZZ – GE engine piston, piston ring, brake disc. Toyota Altezza has developed and produced TiB2/Ti composite exhaust valves [27] by powder metallurgy instead of 21-4 N steel. The high cost of particle reinforced aluminium-based composites limits its largescale production and application in the transportation sector. In the paper [27] the research status of PAMCs preparation and forming technology in recent years is reviewed. Although the preparation and forming process of PAMCs still remain in the laboratory stage, with the continuous maturing of preparation and forming process, the reduction of preparation cost and the new process of new technology have been continuously developed to enhance the aluminium matrix composites will be its excellent characteristics in the automotive and aerospace, aerospace, military and other high-end areas play a greater role. Primary processes for manufacturing of AMCs at industrial scale can be classified into two main groups (Fig. 9).

Figure 9 – Primary processes for manufacturing of AMCs

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The selection of the processing route depends on many factors including type and level of reinforcement loading and the degree of microstructural integrity desired. Table 2 provides feasibility of various primary processes for manufacturing different types of AMCs.

It is evident from the Table 2, that very often it is possible to manufacture AMC of specific formulation (having the same matrix and reinforcement combination) by more than one route [32].

Table 2â&#x20AC;&#x201C; Primary processing routes of AMCs

Primary processes for manufacturing Blending and consolidation Diffusion Bonding Vapour deposition and consolidations Stir casting/slurs casting Infiltration process Spray deposition and consolidation

3.4

Types of AMCs MFAMCs PAMCs

CFAMCs

SAMCs

Not in practice

In use

Not in practice

In use

Not in practice

In use

Not in practice

In use

Generally not use

In use

Generally not use

In use

Generally not use

Not in practice

In use

Modern polymer and composite materials

The polymer composites in automotive applications today are glass fiber-reinforced thermoset polymers used mostly in non-structural parts of the vehicle especially for low- and mid-volume cars and trucks [33]. Fiberreinforced thermoplastics and, especially, carbon fiber reinforced thermosets show great potential, the latter having twice the weight reduction potential of glass fiberreinforced thermoset polymers. Fiber-reinforced thermoplastics share the advantageous properties of polymer matrix composites and are also recyclable, have indefinite shelf life, and feasible for automated, high volume processing with a potential for rapid and low cost fabrication. The cost is the single most major barrier for the limited application of polymer composites in automobiles today [11].For example, from carbon plastic were made such cars: Chevrolet Corvette, Audi R8 and Lamborghini Veneno.

About 80 % of plastics used in automobiles consist in five types of materials: polyurethanes, polyvinylchlorides, polypropylenes, ABS plastics, fiberglass plastics. The remaining 20 % are polyethylenes, polyamides, polyacrylates, and polycarbonates. Under the fiberglass there is meant any fibrous filler that is impregnated with polymer resins. The most famous fillers are carbon fiber, glass fiber and kevlar. The outer panels of the bodies are made of fiberglass, which provides a significant reduction in the mass of the car (Fig. 10). Pillows and seat backrests, shock-resistant pads made of polyurethane. A relatively new direction is the use of this material for the manufacture of wings, hoods, trunk lid. Polyvinylchloride is used for the manufacture of many fittings (shields, grips) and upholstery materials (fabrics, mats).From polypropylene make body of headlights, steering wheels, partitions and much more. ABS plastics are used for various facing details.

Figure 10 â&#x20AC;&#x201C; Advantages and disadvantages of using glass fiber reinforced plastic for automotive industry

Journal of Engineering Sciences, Volume 4, Issue 2 (2017), pp. F 8â&#x20AC;&#x201C;F 18

F 15

The body of the new electric car BMW i3 is largely made of carbon fiber, which made it possible to increase the weight of the battery by 250–350 kg. In fact, the body is made of synthetic material reinforced with carbon fiber. In the terminology of BMW, a new material is named Carbon Fiber Reinforced Plastic (CFRP). It is very durable and light but expensive composite material with fiberglass reinforced plastic. Some composites contain both carbon fibers and other fibers such as kevlar, aluminum and fiberglass reinforcement. Less commonly used materials such as graphite reinforced with fiberglass or miligraphite fibers reinforced with plastic (fiberglass). The car body of this material is 50 % lighter than steel and 30 % lighter than aluminium. Structural elements of the new material can be easily combined with aluminum body panels or metalized [34]. At the moment, carbon fiber is used for light sports models and for very expensive cars. The process of making car body and other models of carbon fiber plastics or with the content of carbon fiber takes a lot of time, and therefore this way is expensive. However, the study of this material allows you to improve the technology of manufacturing parts from it in the direction of reducing production time. This will allow you to arrange a serial release and lower the price accordingly. Company ZF Friedrichshafen AG has developed a rear suspension for small class cars, where the elastic element is a transverse single-leaf springs made of synthetic material, but not carbon-fiber reinforced. The leaf spring is called the Transverse Composite Leaf Spring and also performs the function of the suspension guide. Such suspension can be applied also for electric cars. As is wellknown, McPherson’s pendant has a widespread distribution, consisting of a single block, which includes a spring springs, and a shock absorber, and quite powerful binding and fixing elements. Polymer materials, mostly made in the form of cast products, films and technical textiles, are highly valued in areas of modern economy in many thanks to their heat resistance, thermal resistance, mechanical strength, dimensional stability, and resistance to chemical reagents, fire and moisture resistance, low specific density and other consumer properties. Along with this, the most important area is constructive details where long-fiber reinforced materials such as Vertron from GE Plastics Deutschland, with excellent shock properties and heat resistance, will be used. The similar characteristics are the long-fiber thermoplastic Celstran, which has found application in the external interface and in the door module of the Jaguar car. Today, due to the usability of the equipment, polymers are required to be used even where they are more expensive. For example, the production of polycarbonate headlamps is 2.5 times more expensive than mineral glass; nevertheless, it leaves this automotive sector. New types of coatings and molding technologies of complex threedimensional parts made of polycarbonate make it possible

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to receive not only light but also extremely durable products. The economical two-component injection molding allows the use of polymers in the exterior of the car. Therefore, the consumer will soon be available lightweight panoramic roofs, luggage compartment covers with integrated locks and handles, etc. The Swiss company EMS-Chemie has developed a polyphthalamide suitable for areas where metals need to be replaced. This polymer, used in the central gearbox switch, replaces ordinary aluminum. Such material is stable in size and wear, while maintaining high pressures and temperatures, with peak values well above 200 °C. Long-lasting loads at temperatures up to 160 °C are possible. In comparison with aluminum structural elements, which require eight technological operations, a polyfetamide component can be made in two operations. Auto experts predict that by 2040 half of all new cars that come down from the conveyor will be hybrid. However, in a hybrid car there is one problem: the battery whose energy is used to operate the electric motor is very cumbersome and difficult, even with the current development of lithium-ion batteries. In Europe, a group of nine automakers are currently testing body panels that can accumulate energy and charge faster than conventional batteries. They are made of polymer carbon fiber and resin; the batteries are sturdy but flexible. Thanks to the development of car weight may fall by 15 % [35]. To the novelties you can add the following [35]: 1. Airless tires. The specific design of tires made of thermoplastic resin, allows you to maintain the weight of the car thanks to the curved spokes. 2. Smart lights. Researchers at the Carnegie Mellon University have developed a headlight system that combines the camera, projector, split-prism and processor, which surprisingly reduces the number of drops in the driver's field of vision; the camera detects drops, the processor determines their future location, the projector in turn “bypasses” particles, covering only what is behind them; with the whole process taking about 13 μs. 3. Hydrophobic windows. Properties to repel water implemented in the model KIA CADENZA 2014.

4 Conclusions Thus, we can conclude that the automotive industry is not standing still and developing to the satisfaction of the consumer who wants a fast and safe car. At the expense of innovative development of automobile industry, it is possible to realize competitive products both on the national and international markets, which will ensure the country’s entry into the international economic community. This leads to the fact that in the production of cars used increasingly new materials that meet modern requirements.

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Trevor English, February 8, Blog, automotive, lightweighting, material. Retrieved from http://manufacturinglounge.com/materials-used-lightweight-cars. 6. Legkiye i prochnyyesinteticheskiyematerialy v avtomobilestroyenii [Lightweight and durable synthetic materials in the automotive industry]. Retrieved from http://100ls.ru/index.php/novosti/proizvodstvo/119-legkie-i-prochnye-sinteticheskie-materialy-vavtomobilestroenii [in Russian]. 7. Monteiro, W. A., Buso, S. J., & Silva, L. V. (2012). Application of Magnesium Alloys in Transport. New Features on Magnesium Alloys. Chapter 7. DOI: http://dx.doi.org/10.5772/48273. 8. Steel Applications. Retrieved from https://www.thebalance.com/steel-applications-2340171. 9. Kozlowski, M. (2012). Lightweight Plastic Materials. Thermoplastic Elastomers. Retrieved from http://www.intechopen.com/books/thermoplasticelastomers/lightweight-plastic-materials. 10. Mavhunguа, S. T., Akinlabib, E. T., Onitirib, M. A., & Varachiaa, F. M. (2017) Aluminum Matrix Composites for Industrial Use: Advances and Trends. Procedia Manufacturing, Vol. 7, 178–182. DOI: https://doi.org/10.1016/j.promfg.2016.12.045. 11. Das, S. (2000). The cost of automotive polymer composites: a review and assessment of doe’s lightweight materials composites research – ORNL, TM-2000, pp. 283. 12. Top 5 Materials Used in Auto Manufacturing. Retrieved from https://auto.howstuffworks.com/under-the-hood/automanufacturing/5-materials-used-in-auto-manufacturing. 13. Iz chego delayut kuzova avtomobiley? Retrieved from http://amastercar.ru/articles/body_of_car_3.shtml [in Russian]. 14. Kuzovnoye materialovedeniye [Body Material Science]. Retrieved from https://www.autocentre.ua/opyt/tehnologii/kuzovnoematerialovedenie-286800.html [in Russian]. 15. Automotive steels for safe and lightweight cars. Retrieved from https://www.ssab.com/products/industries/automotive. 16. Ivanov, V. O., Karpus, V. Ye, Degtyarev, I. M., & Bohdan, V. R. (2015). Tekhnolohiya vyhotovlennya avtomobil’nykh detaley skladnoyi formy [Technology of manufacture of automotive details of composite form]. Zbirnyk naukovykh prats’ Natsional’noyi akademiyi Natsional’noyi hvardiyi Ukrayiny, No. 1 (25), 85–90. 17. Surappa, M. K. (2003). Aluminium matrix composites: Challenges and opportunities. SADHANA, Vol. 28, Parts 1–2, 319–334. 18. Mityaev, A. A., Volchok, I. P., et al. (2014). Kompleksnoe modyfytsyrovanye vtorychnykh sylumynov [Complex modification of secondary silumines]. Nauka ta prohrestransportu. Bulletin of Dnipropetrovsk national university of railway transport, Vol. 54, No. 6, 87–96. DOI: 10.15802/stp2014/33180) [in Russian]. 19. Vakulenko, I. A., Nadezhdin, Y. L., et. al. (2013). Electric pulse treatment of welded joint of aluminium alloy. Nauka ta prohres transportu. Bulletin of Dnipropetrovsk national university of railway transport, Vol. 46, No. 4, 73–82. DOI: 10.15802/stp2014/33180. 20. Pietrowski, S., Gumienny, G., Pisarek, B., & Wladysiak, R. (2004). Kontrola produkcji wysokojakosciowych stopow odlewniczych metoda ATD –Archiwum technologii maszyn i automatyzacji, Vol. 24, No. 3, 131–144 [in Poland]. 21. Volchok, I. P., & Mitiaiev, O. A. (2003). Modyfikator dlia aliuminiievykh splaviv [Modifier for aluminium alloys]. Patent UA, No. 2002108343. 22. Volchok, I. P. Mitiaiev, O. A., Ostrovska, A. Ye., & Skuibida, O. L. (2009). Modyfikator aliuminiievykh splaviv [Modifier of aluminium alloys]. Patent UA, No. u200902454. 23. Shyrokobokova, N. V., Mitiaiev, O. A., et al. (2012). Rafinuvalno-modyfikuvalnyi kompleks dlia aliuminiievykh splaviv [Refining and modifying complex for aluminium alloys]. Patent UA, No. u201112705. 24. Belikov, S., Volchok, I., & Mityayev, O. (2006). The nanomodifier of aluminium alloys. Aims for future of engineering science, pp. 191–193. 25. Volochko, А. . (2015). Modifitsirovaniye evtekticheskikh i pervichnykh chastits kremniya v siluminakh. Perspektivy razvitiya [Modification of eutectic and primary silicon particles in silumin. Prospects for development]. Casting and metallurgy, Vol. 81, No. 4, 38–45 [in Russian]. 26. Telang, A. K., Rehman, A., Dixit, G., & Das, S. (2010). Alternate materials in automobile brake disc applications with emphasis on Al composites – a technical review. Journal of Engineering Research and Studies, Vol. 1, Issue 1, 35–46.

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27. Tian, X., Zhu, A., Wei, J., & Han, R. (2017). Preparation and Forming Technology of Particle Reinforced Aluminum Matrix Composites. Materials Science: Advanced Composite Materials, Vol. 1, Issue 1, 1–9. 28. Mironova, E. V., Zatulovsky, A. S., Kosinskaya, A. V., & Zatulovsky, S. S. (2006). Lityye kompozitsionnyye materially na osnove alyuminiyevogo splava dlya avtomobilestroyeniya [Cast composite materials based on aluminium alloy for automotive industry]. Bulletin of Kharkov National Automobile and Highway University, No. 33, 20–22 [inRussian]. 29. Kalinina, N. E., Beloyartseva, V. P., & Kavats, O. A. (2006). Modifitsirovaniye liteynykh alyuminiyevykh splavov poroshkovymi kompozitsiyami [Modification of cast aluminum alloys by powder compositions]. Bulletin of Engine Building, No. 2, 193–195 [in Russian]. 30. Stetsenko, V. Yu., Rivkin, A. I., Gutev, A. P., & Konovalov, R. V. (2009). Modifitsirovaniye siluminom s melkokristallicheskimi alyuminiyevymi splavami [Modification of silumin with fine-crystalline aluminium alloys]. Bulletin of Gomel State Technical University named after P. O. Sukhoi, No. 1, 21–24 [inRussian]. 31. Meenakshi, S. U. & Mahamani, A. (2015). Development of Carbon Nanotube Reinforced Aluminum Matrix Composite Brake Drum for Automotive Applications. Research and Innovation in Carbon Nanotube-Based Composites. Retrieved fromhttp://www.academicpub.org/amsa. 32. Canter, N. (2016). Light weight self-lubricating metal matrix composites. Tribology & Lubrication Technology, pp. 18–19. 33. Timoshkov, P. N., Khrulkov, A. V., & Yazvenko, L. N. (2017). Kompozitsionnyye materialy v avtomobil’noy promyshlennosti [Composite materials in theautomotive industry]. Proceedings of VIAM, Vol. 54, No. 6, 61–68 [in Russian]. 34. Gribkov, A. A. (2013). Novyye materialy, primenyayemyye v avtomobil’noy promyshlennosti [New materials used in the automotive industry]. Materials of the international scientific and practical conference “Innovations in the automotive industry”, pp. 18–22 [in Russian]. 35. 10 tekhnologiy avtomobiley budushchego [10 Future Car Technologies]. Retrieved from http://www.lookatme.ru/mag/live/ futureresearch/197165-future-car-technologies [in Russian].

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JOURNAL OF ENGINEERING SCIENCES УРНА ІН

Н РНИХ НАУ УРНА ИН

Н РНЫХ НАУ Web site: http://jes.sumdu.edu.ua

DOI: 10.21272/jes.2017.4(2).g1

Volume 4, Issue 2 (2017) UDC 504.054

Modeling of waterborne pollution of roadside soils Plyatsuk L. D., Vaskina I. V.*, Kozii I. S., Solianyk V. A., Vaskin R. A., Yakhnenko O. M. Sumy State University, 2 Rymskogo-Korsakova St., 40007, Sumy, Ukraine Article info: Paper received: The final version of the paper received: Paper accepted online:

Corresponding Author’s Address:

October 26, 2017 November 25, 2017 December 2, 2017

irulik.vaskina@gmail.com

Abstract. Motor transport and road maintenance are the determining factors of environmental pollution in the roadside zone. The main acceptor of pollution in this case is the soil. In connection with the complexity of the application of instrumental control methods, it is perspective to carry out the monitoring of roadside territories on the basis of mathematical modeling. The objective of the study is to develop a model of vehicle emissions impact on roadside soils with washout from the road bed. As a physical model we will consider roadside underlying surface covered with a layer of raindrops. According to the physical model, pollutants are absorbed by rain drops when falling on the underlying surface. Movement of pollutants down the whole depth of soil profile is carried out under the action of filtering the contaminated liquid in the granular material of soil. Analytical dependencies have been obtained allowing to predict the roadside ecosystem pollution from exhaust emissions. Soil contamination with liquid effluents resulting from the dissolution of sulfur dioxide in atmospheric precipitation has been calculated.

Keywords: motor transport, exposure, pollutants, migration, soil profile, concentration, filtration, diffusion, sulfur dioxide.

1 Introduction

2 Methods

Motor transport and road maintenance are the determining factors of environmental pollution in the roadside zone, as they provide the environment with huge amounts of dust, soot, waste gases, oils, heavy metals and dozens of other toxicants. The threat of irreversible degradation of biosystems under the intensive influence of vehicles requires the level of their pollution to be forecasted and the adverse consequences to be prevented. It is perspective to carry out the monitoring of roadside territories on the basis of mathematical modelling. However, the adequacy of the model should prove to be true instrumentally and assume subsequent environmental monitoring with the employment of computer capabilities. The objective of the study is to develop a model of vehicle emissions impact on roadside soils. Apart from the atmospheric pollution, washout from the road bed, that is, pollution through water also should be considered. This is the task of the given study.

The main criteria for the environmental quality of the roadside territories are concentrations of nitrogen dioxide, heavy hydrocarbons, carbon monoxide and sulphur dioxide, heavy metals, as well as the pollutants flux density falling on the underlying surface and moving into the ground with liquid rainwater [1]. The most unfavourable factor combination along motor ways emerges in places passing through inhabited areas, areas with large slopes, intersections at grade [2]. Roadside contamination monitoring is usually restricted to determining the concentrations of pollutants in the air, soil and plants [2]. Its implementation results from instrumental measurements of the main parameters included in the criteria for determining the quality of the ambient air and the biosphere. It should be noted that the instrumental method is very expensive and laborconsuming. The organization of soil monitoring provides for a comprehensive solution of the issues related to the determination of the actual pollution level, the forecast of potential contamination in the future, available and predictable consequences of this pollution.

Journal of Engineering Sciences, Volume 4, Issue 2 (2017), pp. G 1–G 5

Models are built with certain assumptions according to the solution of the specific assignment. A detailed classification of such mathematical models is resulted in the monograph [3]. The most well-known implementations of such models are software products Amerod, Calpuff, ADMS-3, Caline3, OCD. The majority of the developments on the given subject are based on the diffusion equation of a pollutant in soil under the action of filtration and adsorption [4]. This approach is completely justified and logical.

where ρg (mg/ml) is the gas density under the following conditions: temperature 0 °C, pressure 101 325 kPa. Movement of pollutants down the whole depth of soil profile is carried out under the action of filtering the contaminated liquid in the granular material of soil. We assume that the diffusion coefficient D in the direction perpendicular to fluid motion is equal to 0. With reference to the rate of filtration, the equation of pollutant motion in the water moving through the interstices of soil will be written as follows:

3 Results

As a physical model we will consider roadside underlying surface covered with a layer of raindrops. According to the physical model, pollutants are absorbed by rain drops when falling on the underlying surface. Let us calculate the initial concentration of pollutants in rainwater runoff, which is predetermined by their concentration in the air. The concentration in rain drops depends first of all on the absorption rate α, mg/(s·m3), as well as water solubility of contaminants R, mg/l. Let us admit that a raindrop falls with a uniform velocity q, m/sec, from height b. Then, over the fall time b/q absorbs the following amount of gas: b G   · ·V , q

CL  2 CL C D   L   CL 2 t Z Z

where λ – gas adsorption rate by the surface soil particles, expressed in fractions in the unit of time, sec-1; m – soil porosity: m

V1 V

(4)

where V1 – pore volume; V – total amount of porous soil. Material balance results in the bond between the concentration of pollutants in the wet soil S (mg/kg), and in water in soil pores L (mg/l):

(1)

where V is droplet volume in which the pollutant concentration becomes equal to α∙b/q. At the same time, the limiting value of pollutant concentration in a raindrop is practically not achievable, since it is restricted by its solubility in water R, mg/l. According to [5] sulphur oxides have the highest solubility, while water solubility of nitrogen and carbon oxides is by an order lower. With increase in temperature, the water solubility of pollutants decreases except lead compounds, for which solubility rises with temperature increase. For the initial pollutant concentration in water with reference to solubility, we obtain the following values:

(3)

CS 

S

(5)

where ρS – soil bulk density, kg/l. One has to bear in mind that from the total concentration,in the form bound with hard soil frame there is a share of pollutants equal to the following integral t

 C d S

Considering V, m, D, , 0, 1 as constants, and having set the edge conditions (initial L = 0 at t = 0, Z > 0, boundary L = С1 at х = 0, t > 0) let’s apply the Laplace transformation to the equation (3): 

b  b  · q ·V ,  q   g R;  G     R,  b   R . g  g q

L  CL    e pt CL  t , z  dt  C (p, z) 0

(2)

By means of Laplace transforms with reference to numeric constants, characterizing the processes of filtration, diffusion and absorption and taking into account soil properties, we’ll obtain the final decision in originals:

   z  2t      2  t  D  CL (t, z)  C0 exp      erfc    exp  z  D   4D  m   D  2t m    t  z   z  m  exp    erfc   Dt   2D     m

  t   C0 exp       m  

      1  z  2t  z       D   exp    erfc    C1  exp   z D  2   2D     D   2t   m    

Environmental Engineering

(6)

  t  z z   m   exp   erfc    Dt  2D      m

(7)                   

where α = λ + 0.25υ2/D. One of the main properties of soil is its porosity (duty factor) – , representing the ratio of the pore volume Vp to the total volume of soil V: 

(8)

  k

The study of pollutant migration mechanism from literature sources [6] shows, that they move in the soil profile with gravitational water under the action of pressure difference. Alongside with soil porosity, one should take into account the surface porosity – m, which is meant as the ratio of pores area Sp to the entire sectional area S: m

To obtain an equation characterizing water layer extension into the ground, let’s direct the OZ axis downward, and the origin of coordinates will be counted from the ground surface. Then the filtration equation can be rewritten as:

a t  

dh   k dl

(10)

(14)

where h = p/γ – z. It results from the continuity equation that the filtration rate depends only on the time t and does not depend on z, therefore, in view of the fact that the head h is a linear function of z. When z = y, pressure is determined by (11). Then

(9)

Solution of the filtration rate equation shows that the average volume porosity  coincides with the average surface porosity m. Filtration occurs under the action of pressure difference. For small pressure heads which are observed in the roadside soils, Darcy’s law is used for filtration rate:

h z

h  z

H  hk  y 



(15)

We have an obvious ratio for the filtration rate:

m

dy dt

(16)

Comparing (12) and (13), we obtain the equation in order to determine the percolation depth у(t): dy m k dt

qt  y 1  m   hk 



(17)

where h = z + p/γ – hydrostatic head; k – filtration coefficient depending on temperature. Darcy’s law is true at Reynolds number Re = ϑd/V less than 3–10, that is at ϑd  0.070–0.075, because of ϑ = 0.018 sm2/s. According to rainwater runoff transport mechanism, water elevation through capillaries occurs under the action of surface tension forces 2/g to the height hk:

which gets integrated provided that у = 0 at t = 0. The above ratios are true only at t < 20 min., that is during rain. Once the rain is over (i. e., 20 minutes later), instead of proportion (13) into the equation (15), it is necessary to put

P  Pa   hk

H  H 20  m  y20  y 

(11)

The rate of filtration depends on the intensive intake of rainwater on the soil surface. To calculate filtration, the value of q20 (20 minutes of atmospheric precipitation for our locality with one-year single exceeding) will be taken as rain intensity. At the same time, the formation of surface runoff with a flow rate should be taken into account, and water will penetrate into the soil with the intensity q equal to

q  q20

(12)

where F – runoff area. By the time t, there will be accumulated a rainwater layer qt thick, part of it H will be located above the ground surface, while the other part will penetrate into the ground to the percolation depth y(t). At each moment of time the equality is implemented: qt  H  t   m  y  t 

(18)

Here у20, Н20 – values of h(t) and H(t) at t = 20 min. The ratio(18) expresses the mass balance. In this respect the equation (15) takes the following form:

dy m k dt

H 20  m  y20  y 1  m   hk 



(19)

provided that y20 = y at t = tR, where tR = 20 min – the duration of rain. The solution of (19) is the integral k  t  tR  

1  m 

 n  y 1  m   (20) 1  m    y  y20   n ln  n  y20 1  m   

where

(13)

Journal of Engineering Sciences, Volume 4, Issue 2 (2017), pp. G 1–G 5

n  H 20  m  y20  hk 



(21)

The solution of (20) is true up to the time tL, when Н = 0, i. e. water is not available above the ground. With reference to (18) у = уL will acquire a value yL  y20 

H 20 m

(22)

Inserting(22) into the solution(20), we will obtain:

tL  tR 

m k 1  m 

At a time interval tL < t < tR, the filtration rate value ϑ is considered equal to the mean value of m·dy/dt, which can be represented by way of increment of function in the form

yL  y20 tL  tR

(24)

After point of time tL, the equation describing the further pollutant invasion into soil remains the same, but the solution must take into account the mobility of the upper edge for soil wetting.

4 Discussion To verify the model adequacy, we calculated the concentrations of L by the equation (8) for the following initial data: ─ the rain intensity was assumed to be 0.0001 m/sec = = 0.36 m3/h (low intensity rain); ─ the content of SO2 in rainwater is taken equal to the limiting solubility of sulfur dioxide at ambient temperature of 15 °С: R = 47.3 ml/l; ClSO2 = ρ – R = = 2.9266 – 27347.3/288 = 131.2 (mg/l) = 1 (z = 0, t > 0); ─ soil-clay loam: for porosity m = 0.35 we have k = 10-6 m/sec = 0.003 m/hr [4]; ─ capillary lift height hk = 2.25 m; mass transfer coefficient  = 1.6Rе0.54D/d2 = 0.04 m/sec at d = 0.002 m, V = 10-6 m2/s, W = 1 m/s, D = 2·10-9 m2/s – diffusivity of gases in water [7].

Environmental Engineering

Table 1 – The calculation of SO2 concentrations in rain drops with rain intensity of R = 0.36 m3/hr Time, s

  H   n   y20  20  1  m   (23)  H 20 m   1  m    n ln m n  y20 1  m       

m

While substituting the design data into (7), we obtain the values 2 L/С1 and L for two variants. The results of the calculation are given in Table1.

10 15 20 25 30 60 600

Coordinate Z = 0.01 m 2 L/ CL, ml/l 0.0712 4.67 0.184 12.07 0.25 16.4 0.177 11.61 0.1494 9.80 0.147 9.64 0.142 9.32

Coordinate Z = 0.02 m 2 L/ CL, ml/l 0.000271 0.0178 0.0050 0.328 0.00563 0.369 0.0164 1.08 0.0264 1.732 0.0408 2.676 0.0221 1.45

Studies have shown that with the change in rain time, the concentration of sulfur dioxide in puddle raindrops, located at the distance of 5 m from the highway roadbed edge, increases to maximum, after that the concentration decreases. At the same time, the concentration of sulfur dioxide within the depth of the soil profile decreases by almost an order of magnitude changing Z in a range from 1 to 2 cm. It should be noted that within 20–30 seconds after rain starts, the concentration in the puddle on the surface reaches 16 mg/l.

5 Conclusions Within the undertaken study, there has been developed a mathematical model for pollutants solubility in liquid rainfall run-off. Analytical dependencies have been obtained allowing to predict the roadside ecosystem pollution from exhaust emissions. Soil contamination with liquid effluents resulting from the dissolution of sulphur dioxide in atmospheric precipitation has been calculated. Moreover, the strong side of the model is its relative easy for programming in Mathematics application packages (e. g. MATLAB, Maple).

References 1. Vnukova, N. V., & Zhelnovach, G. M. (2011). Vybir ekologichnoznachymyh parametriv avtotransportnyh system dlya ocinky ekologichnoyi nebezpeky prydorozhnogo prostoru. [Selection of environmentally significant parameters of motor transport systems for assessing the ecological danger of roadside space]. Ecological safety, Vol. 2 (12), 119–123 http://www.kdu.edu.ua/ EKB_jurnal/2011_2(12) [in Ukrainian]. 2. Lukanin, V. N., Buslaev, A. P., Trofymenko, Y. V., & Yashyna, M. V. (2001). Avtotransportnye potoki i okruzhayushhaya sreda [Road traffic and the environment]. Moscow, Russia [in Russian]. 3. Babkov, V. S., & Tkachenko, T. J. (2011). Analiz matematicheskih modeley rasprostraneniya primesey ot tochechnyh istochnikov [Analysis of mathematical models of the spread of contaminants from point sources]. Donetsk, Ukraine [in Russian]. 4. Polubarynova-Kochyna, P. Ya. (1977). Teoriya dvizheniya gruntovykh vod [Theory of groundwater movement]. Moscow, Russia [in Russian]. 5. Nahaev, Z. N. (2003). Tehnogennoe vozdejstviye avtomobil’nykh dorog na ekosystemy prydorozhnoj polosy [Technogenic impact of motor roads on the roadside system]. Proceedings of the Forest Engineering Department PetrSU. Petrozavodsk, Russia, pp. 1–3 [in Russian]. 6. Yurchenko, V. A., & Mykhajlova, L. S. (2012). Osobennosti tekhnogennogo zagryazneniya pridorozhnogo prostranstva nefteproduktami [Features of technogenic contamination of roadside space by oil products]. Scientific Herald of Construction, Vol. 69, 404–407 [in Russian]. 7. Fylyppov, V. V. (1990). Ekologicheskiye raschoty pri proektirovanii dorog [Environmental calculations for road design].Car roads, Vol. 5, 20–21 [in Russian].

Journal of Engineering Sciences, Volume 4, Issue 2 (2017), pp. G 1–G 5

JOURNAL OF ENGINEERING SCIENCES УРНА ІН

Н РНИХ НАУ УРНА ИН

Н РНЫХ НАУ Web site: http://jes.sumdu.edu.ua

DOI: 10.21272/jes.2017.4(2).g6

Volume 4, Issue 2 (2017) UDC 66.021+66.048.3

Modelling of the vertical migration process of phosphogypsum components in the soil profile Chernysh Ye. Yu., Plyatsuk L. D., Yakhnenko O. M., Trunova I. O.* Sumy State University, 2 Rymskogo-Korsakova St., 40007, Sumy, Ukraine Article info: Paper received: The final version of the paper received: Paper accepted online:

Corresponding Author’s Address:

October 5, 2017 November 26, 2017 December 2, 2017

inna.trunova@ecolog.sumdu.edu.ua

Abstract. This paper focuses on the study of the process of vertical migration of phosphogypsum components according to the soil profile. The qualitative and quantitative identification of main biogenic elements (phosphorus, sulphur, calcium etc) and heavy metals in lysimetric solutions from various horizons while getting on the surface of soil solutions containing phosphogypsum components is carried out by means of designed laboratory and experimental complex. The mineral hard soil fraction is also analysed. According to the results of the X-ray diffractometrical researches, the carbonates with heavy metals in their structure, caused by the ion-exchange with Са2+, were found in the mineral structure of the illuvial horizon soil samples. The results of experimental modeling indicate significant changes in the chemical parameters of groundwater, which are obtained by passing water with phosphogypsum particles on a model soil profile, which makes it easy to track the input data. In the upper part of the profile after 1 000 hours and for the first speed of the infiltration process, the constant moisture level was 25,6%, after the second speed of infiltration, it rose to 29.1 %. Noted that the highest concentration of biogenic elements (calcium, sulfur, potassium) was found in lysimetric solutions obtained from the humus and eluvial horizons. In addition, it is determined that iron is present up to 5 %, nickel – within the range of 1–3 %, and copper – up to 1 %. It should be noted that the biochemical transformations of silicon influence the fractional distribution of heavy metals, which can be fixed by sorption-sedimentation mechanisms in silica, oligo and polysilicon compounds, as well as in crystalline lattice structures of clay minerals, quartz, etc. The model of soil and geochemical situation was formed according to the soil profile under the influence of the phosphogypsum within the three-dimensional surface, developed with the help of the stochastic reconstructions based on the images of the scan electron microscopes. Keywords: modeling, vertical migration, moistening, phosphogypsum, heavy metals, soil profile.

1 Introduction The environmental concerns associated with phosphogypsum stacks include fluoride uptake, ground and surface water pollution if located nearby. Main vectors for their transport into the environment are wind and water erosion, infiltration, leaching into surface and ground water and airborne emissions of gaseous and radioactive elements. Fine particles of phosphogypsum can be picked up and transported by wind and vehicular traffic on stacks into adjacent areas. Dust particles containing fluoride is a concern for operational and non operational stacks. Elevated levels of fluoride have been found in soil/vegetation adjacent to the stacks. Disposal of phosphogypsum on land may pose seepage problems beneath the repositories or the process water holding ponds if not lined or controlled properly. Phosphogypsum stacks up to a height of 20 m are in operation in the country. The water stock from phosphogypsum

Environmental Engineering

cannot be discharged as such as it contains significant quantities of fluorine and phosphates as P 2O5. The outer dikes are generally earthen dikes designed to prevent the escape of contaminated water into nearby streams. Fluoride contaminant present in phosphogypsum may attack silicate minerals and dissolve them [1].

2 Background The huge amount of scientific works was dedicated to the studying of the environmental contamination in phosphogypsus (PG) heaps keeping areas or during its direct application in the agriculture and road building. It is caused by the possibility of application of certain amount of heavy metals (HM) along with phosphogypsum into ecosystems amplifying their migration in the soil environment by means of soil solution souring with phosphogypsum, getting into trophic chains, and increasing of anthropogenic pressure on ecosystems [2–9].

A set of known heap monitoring directions, including PG and anthropogenic massifs, deal only with geodesic studies. The aim of such a geoecological monitoring is a geomechanical processes status that takes place in massifs to avoid uncontrollable catastrophical processes as landshifts and landslips, and to guarantee the forming quarries and heaps side stability [10, 11]. Another application of geodesic studies is the security monitoring during the formation of PG heaps including hydromechanical, geodesic and technological components [12].

3 The objectives of the study The aim is to study the process of vertical migration of PG components according to the soil profile. The following tasks were included: ─ to elaborate the laboratory and experimental complex aimed at migration process modeling and PG components transformation in the soil profile; ─ to make a model of grey forest soils according to the depth with a formation of a frontal moisturizing progression; ─ to make a model of migratory process connected with PG components during filtration through soil profile of water containing fine PG elements.

4 Materials and methods Complicated mechanisms of chemical elements distribution in soils under influence of natural and anthropogenic factors intricate the process of prediction concerning location or distribution of some chemical substances in the soil profile. It is confirmed by the results as for indication of heavy metals content in the natural soil solutions from adjacent to a humid territories. It was determined that under the influence of atmospheric precipitation, evaporation and transpiration of plant groups, the dynamics of change in concentration of trace elements in soil solutions may change by more than an order of magnitude. Under analogical conditions, the concentration of main macroelemental ions (Са2+, Mg2+, K+, NO-3 і PO43-) is less changeable. Accordingly, the module of laboratory-experimental complex was elaborated for the regulation of multi-factored effect that is caused by PG and its composite materials to biogenic elements and heavy metals migration. Figure 1 shows elaborated laboratory-experimental complex. The module of the soil profile, created accordingly to natural genetic horizons from a territory of natural ecosystems near the PG dumb, was in the tube of organic glass. The measurement of module work part: length × width × height: 40 cm × 30 cm × 75 cm.

Figure 1 – laboratory-experimental complex concerning a modeling of migration and transformation process of the phosphogypsus components in the soil profile: a – the scheme of the laboratory-experimental complex with soil horizons: H – humus; E – eluvial; I – illuvial; D – maternal breed; b – the photo of the laboratory-experimental complex; the channels of lysimeter solution are indicated with arrows

A module surface with soil was sprinkled with phosphogypsis solution. The sensor system contained detectors of moisture and temperature. Microcontroller Arduino Uno (licensed) was used for rate control. A constant supply of solution by a pump to the top surface of the soil was implemented with the usage of peristaltic pump Masterflex® L / S. A selection of the filtrated solu-

tion samples was implemented in the depth of the soil profile 10, 20, 40 and 60 cm due to lysimeter. During this process, the drainage of the solution from the lysimeters took place according to a principle of drift with help of output channels, that ended with polymeric tubes. Lysimeters were pallets that had a form of a funnel (truncated conus with a trivet on the top). These pallets

Journal of Engineering Sciences, Volume 4, Issue 2 (2017), pp. G 6–G 11

were connected with an output of water receiver with the help of a small glass pipe. The funnels were filled up with a drainage and were inserted into other tubes according to the depth of the soil profile. The soil in the lysimeters was in suspended state, where the forces of a capillary adhesion on the border of the soil-drainage or soil-air are absent, that is why the water drain was slowing down [13]. There was carried out qualitative and quantitative determination of the main biogenic elements (phosphorus, sulfur, calcium, etc.) and heavy metals in lysimetric solutions from various horizons with the help of X-ray fluorescence analysis method, and there was controlled pH value. In addition, the diffractometrical method helped to perform an analysis of the mineral solid fraction of the soil beyond the genetic horizons.

5 Results Measuring the moisture content in different places on the soil surface showed that the water distribution is relatively equal. The inflow and outflow of aqueous solution for the soil profile are shown in Fig. 2. In this study, there were used two stages of the water inflow containing fine-dispersed particles of phosphogypsum. The first stage included a constant inflow speed 9·10–8 m / s as long as there was no persistent leak, which required about 1 250 hours. At the second stage, a higher speed was applied 5·10–7 m/s and lasted as long as no persistent leakage was observed after about 2 000 hours. According to the results of X-ray fluorescence analysis, the elements distribution in lysimetric solutions according to the horizons was determined (Fig. 3).

Figure 2 – The inflow and outflow of aqueous solution for the soil profile model

Figure 3 – The ratio of elements in lysimetric solutions samples from different depths based on the soil profile model, %: a – from the genetic horizon H, 10 cm; B – from the genetic horizon E, 20 cm; c – from the genetic horizon I passing to P, 40 cm

The dynamics of the main elements distribution in lysometric solutions is presented in Table 1. As can be seen from Fig. 3 and Table 1, the highest concentration of biogenic elements (calcium, sulfur, potassium) was found in lysimetric solutions obtained from the humus and eluvial horizons. In addition, it is determined that iron is present up to 5 %, nickel – within the

Environmental Engineering

range of 1–3 %, and copper – up to 1 %. In the whole, the concentration of these elements fluctuates in the abovementioned limits according to all rare samples from different genetic horizons. In lysimetric solutions, no lead and cadmium were detected, which is the evidence of absence of water-soluble forms of these HM in soils that were irrigated with water containing fine-dispersed parti-

cles of phosphogypsum. This confirms the results of the previous field studies in the territory of the phosphogypsum dump [14], when moving forms of Pb and Cd were detected only under the influence of ammonium-acetate buffer solution. Table 1 – Results of the comparative analysis of the peak intensity of chemical elements in the lysimetric solutions beyond the horizons of the soil profile model (the color indicates the intensity change of the element in the analyzed samples)

Element

13 14 15 16 19 20 22 24 26 28 39

Al Si P S K Ca Ti Cr Fe Ni Cu

Intensity E 29381 248496 682 85087 58394 263970 334 1252 14810 5793 2624

Change in % H I 48 94 34 –100 141 – 26 24 38 66 8 59 51 – 3 55 26 27 8 25 16 –

It should be noted that the samples of lysimetric solutions haven’t been taken from the P horizon because of

the absence of the lysimeter drain that was caused by the water-resistant properties of the clay material within this horizon. The pH value of the lysimetric solutions ranged within the limits of 4.7–5.8 for the H, E and I genetic horizon samples, indicating the acid reactions within the soil medium. However, after the measuring of the PG value of the P horizon soil extract (10 and 5 cm from the basis) indexes came up to the neutral ones (6.4–6.9).

6 Discussion The dynamics of the moistening front during the infiltration process is shown in the Fig. 6. With the reference to Figure 6 one can understand that it would take about 500-550 hours for the moistened surface to reach the basis of the profile. It is also confirmed by the analysis of the diagram № 4, where the drain wasn’t observed for 520 hours. It happens due to the marginal effects within the moisture distribution profile. It didn’t come out of the soil until the profile basis was almost entirely soaked, that was caused by the capillary rupture effect. The capillary rupture takes place when there is a contrast between the size of the interstices located at the horizon interfaces (i.e. fine-grained clay rocks are situated above the relatively large holes within the corresponding plate).

Figure 4 – The front moistening progression

In the upper part of the profile after 1 000 hours and for the first speed of the infiltration process, the constant moisture level was 25.6 %, after the second speed of infiltration, it rose to 29.1 %. The two above mentioned stages illustrate that a single pressure gradient is present in the upper part of the soil profile (i. e. the soaking doesn’t change with the depth). In this case, the hydraulic conductivity is equal to the discharges. Taking into account the data obtained, the model of soil and geochemical situation was build according to the soil profile (Fig. 5) under the influence of the PG within the three-dimensional surface, developed with the help of the stochastic reconstructions based on the images of the

SEM (scan electron microscopes), high-resolution photographs (21.0 Mp) and Autodesk 3DS Max software. According to the results of the X-ray diffractometrical researches, the carbonates with heavy metals in their structure, caused by the ion-exchange with Са2+, were found in the mineral structure of the illuvial horizon soil samples. Furthermore, in the lysimetric solutions within this horizon the part of Са made up 48–53 %. The significant content of Ca in the solutions let us conclude as for the possible biochemical processes of its releasing from the phosphogypsum structure due to the action of the rhizosphere microorganisms. It creates the subsurface

Journal of Engineering Sciences, Volume 4, Issue 2 (2017), pp. G 6–G 11

barrier for the migration of toxins downward within the

profile.

Figure 5 – The model of soil and geochemical situation with the structure of the interstices in the fine-grained clay rocks according to the model profile

We determined the stable compounds of SiO2 aluminosilicates, AlO3∙2SiO2∙3H2O and soluble FeO iron oxide forms, that correlates with the data on lysometric solutions. Thus, in the solution of the ilevial horizon there were 5% of the total Fe content, and Si in the water soluble form is only at the level of 1%. In the humus horizon and eluvial, based on the results of lysometric analysis, water soluble forms of silicon (24-31 and 31-38% respectively) were found. It should be noted that the hydroxides and iron oxides play an important role in the sorption of HM, it is related with such formations as FeOMe, (FeO) 2Me, FeOMeON, for example PbFe2O4. The biochemical aspects of the metabolism of silicon are not fully understood today. Si can also interact with phosphogypsum components under the influence of biochemical factors (bacterial metabolites) [15]. It should be noted that the biochemical transformations of silicon influence the fractional distribution of HM, which can be fixed by sorption-sedimentation mechanisms in silica (SiO2∙nH2O), oligo and polysilicon compounds, as well as in crystalline lattice structures of clay minerals, quartz, etc. It should also be noted that the significant content of sulfur compounds in water-soluble form (sulfate ions), which was observed in accordance with the results of the study, may be the result of the action of the biotic component of the soil complex on fine particles of PG, which came from the water in the profile of the model soil. Accordingly, this is a confirmation of the possibility of using the components of phosphogypsum in the metabolic activity of soil bios.

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7 Conclusions We accomplished the simulation of moisture of gray forest soils at depth during filtration through the soil profile of water containing fine particles of phosphogypsum. This made it possible to investigate the dynamics of the moisture front during the infiltration of the aqueous solution as a model of runoff of contaminated water from an array of PG dumps. The results of experimental modeling indicate significant changes in the chemical parameters of groundwater, which are obtained by passing water with PG particles on a model soil profile, which makes it easy to track the input data. The main changes in the soil system can be characterized as a change in pH, an increase in dissolved ions, especially sulfates and phosphates, but also in metal ions, and an increase in dissolved silicon dioxide. Increased concentrations of many ligands lead to significant changes in the predicted equilibrium complexation. In this case, the highest concentration of nutrients (calcium, sulfur, potassium) in soil solutions is obtained from the humus and eluvial horizons of the model soil profile. One can assume that the most expressed growth of metal complexes with sulfate and phosphate leads to the formation of uncharged or negatively charged types of solutions that are likely to be more mobile in the aquifer than positively charged metals. Although the results of the model should not be considered to be final, taking into account the various potential solid phases that may be formed, the general trend of predicted transformation reactions in the soil system indicates the precipitation reaction of various, and probably multicomponent solids, that should be expected directly in the runoff of polluted water from the PG waste stack.

References 1. Guidelines for Management and Handling of Phosphogypsum Generated from Phosphoric Acid Plants (Final Draft). Central Pollution control board (Ministry of Environment & Forests). Parivesh Bhawan (2012), available at: http://www.cpcb.nic. 2. Folek, S., Walawska, B., Wilczek, B., & Miśkiewicz, J. (2011). Use of phosphogypsum in road construction. Polish Journal of Chemical Technology, Vol. 13, No 2, 18–22. 3. Shen, W., Zhou, M., Ma, W., Hu, J., & Cai, Z. (2009). Investigation on the application of steel slagfly ash-phosphogypsum solidified material as road base material. Journal of hazardous materials, No 164 (1), 99–104. 4. Krainiuk, O. V., Buts, Yu. V., & Kobzin, V. G. (2013). Do pytannia nebezpeky vidkhodiv promyslovosti pry budivnytstvi avtomobilnyh dorih: zb. nauk. pr. Budivnycztvo, materialoznavstvo, mashynobuduvannya, Vol. 1, Issue 71, 153–157. 5. Lyubimova, Y. N., Tersyn, V. A., et al. (2009). Otsenka vliyaniya stroitelstva dorogi s ispolzovaniyem fosfogypsa na zagryaznenye pochv. Byulleten Pochvennogo instytuta im. V. V. Dokuchaeva, No 63, 74–83. 6. Gorlov, A. A., Krechetov, P. P., & Rogova, O. B. (2015). Vliyanye fosfogypsovyh dorog na fiziko-himicheskiye svoystva pochv. Mezhdunarodnaya nauchnaya konferenciya: K 100-letiyu so dnya rozhdeniya akademyka G. V. Dobrovolskogo, pp. 34– 35. 7. Degirmenci, N., Okucu, A., & Turabi, A. (2007). Application of phosphogypsum in soil stabilization. Building and Environment, Vol. 42, No 9., 3393–3398. 8. Papastefanou, C., Stoulos, S., Ioannidou, A., & Manolopoulou, M. (2006). The application of phosphogypsum in agriculture and the radiological impact. Journal of Environmental Radioactivity, Vol. 89, No 2, 188–198. 9. Belyuchenko, Y. S. (2014). Osobennosti mineralnyh othodov v tselesoobraznosti ih ispolzovaniya pri formirovanii slozhnyh kompostov. Nauchnyj zhurnal KubGAU, No. 101 (7), 1–21. 10. Ozhygyna, S. B., Ozhygyn, D. S., et al. (2016). Monitoring sostoyaniya ustoychyvosti karernyh otkosov. Interekspo Geo-Sibir’, pp. 161–166. 11. Korobanova, T. N. (2015). Monitoring opasnyh geodinamycheskih protsessov pry formiovanii otvala fosfogypsa Balakovskogo filiala JSC “Apatyt”. Gorny informatsionno-analitichesky byulleten (nauchno-tehnychesky zhurnal), No 4, 405–408. 12. Kutepov, Yu. Y., Kutepova, N. A., et al. (2013). Organizaciya i provedenie monitoringa bezopasnosti pry formirovanii otvalov fosfogypsa. Gorny informatsionno-analitichesky byulleten (nauchno-tehnychesky zhurnal), No 5, 68–72. 13. Plyatsuk, L. D., Chernysh, Ye. Yu., Yakhnenko E. N., & Trunova, I. A. (2015). Systemny podhod k ekologycheskomu monitoringu v rajone razmeshcheniya otvala fosfogypsovyh othodov. Ekologicheskiy vestnyk (Minsk), No 4 (34), 77–85. 14. Didora, V. G., Smaglij, O. F., et al. (2013). Metodyka naukovyh doslidzhen v ahronomiyi: navch. posib. Centr uchbovoyi literatury. Kyiv, Ukraine. 15. Kolesnikov, M. P. (2001). Formy kremniya v rasteniyah. Uspekhi biologicheskoy khimii, Vol. 41, 301–333.

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JOURNAL OF ENGINEERING SCIENCES УРНА ІН

Н РНИХ НАУ УРНА ИН

Н РНЫХ НАУ Web site: http://jes.sumdu.edu.ua

DOI: 10.21272/jes.2017.4(2).g12

Volume 4, Issue 2 (2017) UDC 621.311.22:614.7

Directions of the environmental protection processes optimization at heat power engineering enterprises Hurets L. L., Kozii I. S.*, Miakaieva H. M. Sumy State University, 2 Rymskogo-Korsakova St., 40007, Sumy, Ukraine Article info: Paper received: The final version of the paper received: Paper accepted online:

Corresponding Author’s Address:

September 29, 2017 November 27, 2017 December 5, 2017

i.koziy@zaoch.sumdu.edu.ua

Abstract. The article observes the impact factors of heat power engineering enterprises on the environment and ways of anthropogenic impact reduction during the application of ecological security control technological methods. The authors suggest attending to the optimization of specific environmental protection processes during the elaboration of ecological security control technical methods in order to reduce the anthropogenic impact on the environment. At the industrial enterprises it is reasonable to implement the principle of the optimization of the environmental protection processes with the help of the high-intensity purification equipment. The optimization of the environmental protection process involves the choice of the physical-chemical factors such as: thermodynamic, kinetic, mass- and heat-exchanging, hydrodynamic, influence parameters on the heterogeneous, complex systems. According to the results of the systems analysis of impact factors on the efficiency of environmental protection processes, it is suggested to optimize the cleaning equipment due to classified and structural parameters, which would allow design the systematic approaches to the selection of environmental protection equipment in future. The process intensity is considered as an environmental protection process optimization criterion. Keywords: ecological security, heat and power engineering, environmental protection processes, optimization, intensity.

1 Introduction Heat and power engineering enterprises, which are the sources of comprehensive environmental contamination, cause the ecological danger formation within industrially developed regions that is connected with the anthropogenic impact on the environment. Nowadays, Ukrainian heat and power engineering enterprises are considered to be main contaminators of the environment. They cause above 30 % of harmful substances emission of the total volume of industrial enterprises emissions [1]. The growing demand for electric power and heat causes the growth of their output that leads to the comprehensive negative impact of heat and power engineering facilities on the environment and the increase of risk for the population living in the CHP influence area. Factors of heat and power engineering enterprises impact on the environment are air emissions, hydrosphere pollution, formation of the huge amount of by-products of various hazard categories significant part of which are slag wastes, various types of physical impacts, such as thermal and acoustic. Famous Ukrainian and foreign scientists including Barieva E. R., Kutovy V. O.,

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Cherentsova A. A., Mylenka M. M., Gorova A. I., Krupska L. T., Zvereva V. P., Kulinenko O. R., Richter L. А. et al. studied the environmental status in the regions, where thermal power plants are located [1–9]. The impact of thermal power plants on the environment significantly differs due to types of fuel. Gas is the “cleanest” fuel for thermal power plants. The “dirtiest” fuel is oil shales, peat, сoal, and lignite. The largest number of dust items and sulfur oxides is formed in the process of burning. The new energetic policy in Ukraine is aimed at the decrease of oil gas сonsumption and at movement to the usage of multi-typed solid fuel. Due to this reason, power system enterprises extensively use the coal for energy production. This leads to the increase of ecological stress for the environment. Growing anthropological burden to the environmental elements provokes resistant changes in the structure and affects their functioning. Environmental pollution is an essential factor of dangers for people’s health. Getting into the environment, some ksenobiotics make a chronic action that causes organismic desadaptation, especially concerning vulnerable people. This situation is a base for development of the

multi-sided approach to ecological safety control, that is based on the in-depth research connected with the conditions of a danger formation and with the domination of technical methods that are directed to regulate the danger state, besides to increase of environmental equipment intensively. Some territory is observed as compound social-natural-anthropogenic complex in the light of research of problems concerning resistant development. This complex is characterized with organic unity of all territorial components. Common mutual connections are being set either in the interior part of these components or between them. Their taking into account allows to investigate changes concerning parameters of human vital activity and environment depending on industrial regional infrastructure. In 1996, EU released the directive “Concerning integrated pollution prevention and control”. According to this directive, a decision about possibility to obtain the integrated permit for omissions, discharge of pollutants and waste disposal are made on the basis of ecological audit of an enterprise when the balance of pollutants is formed for the each kind of an enterprise with accounting of all omissions, discharges and waste. Also, in this case the comparison of ecological indicators is accomplished with the basic indicators “of the best accessible methods” . Energy efficiency of production is also estimated as well as the probability of emergencies, the elimination of their consequences, a plan of a territorial renovation in case of the production closure. According to the term, “the best available methods” are understood as the most effective ways for development. Also, they are methods of a production control that provide the opportunity to prevent omissions and negative factors for the environment, but when all this is impossible – just to decrease a negative effect. The necessary motivation for innovative processes is the adoption of state standards of environmental management [10, 11]. The orientation of industrial production to meet the requirements of these standards allows to optimize and stabilize the operation of the main technological equipment, promotes technical re-equipment of industrial enterprises and improvement of environmental equipment, which leads to compliance with the norms of influence on environment. In works devoted to the development of technical methods of environmental safety management, insufficient attention has been paid to optimization of specific environmental protection processes in order to reduce the technogenic load on the environment. The objective of this paper is to consider the ways of improving the environmental situation in places where heat energy objects are located in terms of optimizing environmental protection processes.

2 Methods The main principles of ecological safety in the system “settlement – industrial enterprise” are based on the following principles: compliance of normative and legislative framework with international requirements; rational

planning of settlements development; minimization of pollutants formation through the improvement of industrial production technologies and implementation of environmental measures, which include upgrading of environmental equipment; integrated approach to the issue of reducing the population morbidity risk of caused by pollution of the environment. In the zone of thermal power plants, according to the intensity of the impact and the nature of the transfer of pollutants one can distinguish the zones of the immediate (core) and indirect effects (Fig. 1), which differ in intensity and limits of influence on environment and people.

Figure 1 – Environmental impact of thermal power plants

One of the ways to increase the level of environmental safety is choosing technologies that are more effective compared with existing environmental ones and which provide normative levels of environmental impact. The task of increasing environmental safety can be reduced to the task of structural elemental optimization of environmental protection processes in general and a separate environmental protection process in particular. The problem of optimization of the environmental protection process is defined in: ─ establishing the criterion of optimality of the environmental protection process; ─ determining the set of parameters X = (X1, X2, ..., Xn) which have the influence on the efficiency of environmental protection according to the chosen criterion; ─ developing the target function F = f (X), solving optimization problem, that is finding the extremum of the target function, and as the result finding one of the possible processes, the parameters of which are the extremum of the target function. As one of the ways to increase the level of environmental safety is to reduce the amount of pollutants entering the environment, optimization of the environmental protection process will be aimed at extracting the largest mass of pollutants for a certain period of time.

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The process of integrated treatment of emissions and discharges of heat power engineering objects should be considered as a purposeful transformation of the physical and chemical system, namely a multi-component continuous medium distributed in the volume of the apparatus, at each point of which the transfer of matter, energy and momentum occurs. Each of the phases can be considered as a transport stream, which introduces one or more reagents into the working area of the apparatus. In the flow of a multi-component mixture, different components move at different speeds, which allow the composition of the mixture to change both in space and time. The effectiveness of environmental processes will be a result of the simultaneous occurrence of physical and chemical processes, the interconnection of which causes the distribution of concentration fields and momentums in the reaction zone of the apparatus. The efficiency of the treatment equipment is determined by the formula:



MB K·F· ·100 %  ·100 % , Mn Mn

(1)

where МB – mass of pollutant extracted per unit time kg/s; Мп – initial mass of pollutant in emissions or discharges, kg/s. The mass of the extracted pollutant is determined from the material balance of the process or by the equation:

M  K·F··t ,

(2)

where М – mass of the collected material, kg; F – phase contact area, m2; K – coefficient of process speed; Δ – the driving force of the process; t – time, s. Mass of the material can be considered as formalized productivity of the apparatus according to a certain type of material. Attributed to a parameter that characterizes the size of the working area of the apparatus, this value allows considering a more important characteristic that integrally reflects the functional and technological level of the process or the apparatus - intensity. The intensity of any apparatus refers to the ratio of one of its target characteristics to the volume or area of the cross-section of the apparatus. The intensity of the work is proportional to the speed of the process; therefore, they seek to create such a design of the apparatus, which would ensure the maximum speed of the process, and, accordingly, the maximum intensity. Being one of the essential conditions of the industrial equipment tech level improvement, intensity gives us the possibility to increase the amount of products manufactured in the same period of time, to reduce the amount and the dimensions of the equipment units. At the industrial enterprises it is reasonable to implement the principle of the optimization of the environmental protection processes with the help of the high-intensity purification equipment. In such case one should view the optimization process as the solution of the optimization

G 14

Environmental Engineering

problem, taking the intensity as the optimization variable of the purification equipment referred to [12]. The intensity of the equipment unit is calculated using the formula:

M   K ·F · ; V ·t V M  i  K ·F · , S·t S i

(3)

where V – capacity of the equipment unit, m3; S – cross-sectional area of the equipment unit, m2. The environmental protection process P, which has the maximum intensity, would be the most preferable one:

P  max i  X  .

(4)

where X – factors which influence the intensity of the process. The optimization of the environmental protection process involves the choice of the physical-chemical factors such as: thermodynamic, kinetic, mass- and heatexchanging, hydrodynamic, influence parameters on the heterogeneous, complex systems. The thermodynamic factors, combining features of both phase and chemical equilibrium, determine the technological parameters and the direction of the implementation of the process, its speed and selectability. The kinetic factors, in their turn, involve kinetic constant and the energy of the reaction activation within the system. The group of massexchanging factors is represented by the interphase transfer coefficient of all the initial, intermediate and final substances. The heat-exchanging factors include heattransfer coefficient and the characteristic of the external heat-exchange of the system with the surrounding. The hydrodynamic factors are defined as the characteristic of the interface formation, linear momentum, the turbulization of gas and liquid phase flow. However, the sphere of their indirect influence increases significantly due to the integrated speed of mass- and heat transfer and chemical reactions. The particular group is represented by the constructive factors the connection with physical-chemical phenomena of which and their influence on the heterogeneous complex systems is manifested in the instrumentation of the operating space of the equipment unit. These factors correspond to the structurally represented techniques, which influence the interphase transfer processes via the hydrodynamic factors and the formation of the developed contact phase surface. The predominant sphere of the manifestation of the constructive factors is the formation of the energy expenses related to the arrangement of phase movement in the equipment unit. Thus, they have a significant influence on the optimization indexes within the gas purification process. Using the principles of system approach and structural optimization, factors that influence on the process of optimization of gas-cleaning processes, based on equation (2), can be represented by the following interconnected and at the same time functionally completed subsystems:

1 – subsystem of factors that lead to an increase in the surface area of phases contact; 2 – subsystem of factors that lead to an increase in average driving force; 3 – subsystem of factors that lead to an increase in the coefficient of process speed; 4 – subsystem of factors that affect the volume of the device. The first subsystem includes two types of factors: hydrodynamic methods and constructive methods. As components, they are interconnected and affect both each other and the subsystem.

X 1  f Re,  ,

(5)

where Re is the Reynolds criterion; Г – characteristic of the constructive parameters of the apparatus. The subsystem of factors that lead to an increase in the average driving force of the process is represented by three groups: hydrodynamic methods and physical and chemical properties of the phases, technological parameters of the process:

X 2  f Re, ,   ,

(6)

where Ф is a component that takes into account physical properties of the phases; П is the technological parameters of the process. The subsystem of factors that lead to an increase in the mass transfer coefficient is represented by groups: hydrodynamic methods; physical and chemical properties of phases; technological parameters of the process:

X 3  f Re, ,   ,

(7)

The fourth subsystem of factors X4 – factors of influence on the volume of the apparatus. Reducing the volume of the device happens due to increasing the speed of gas (reducing the area of the crosssectional area of the device at a steady flow) and the effectiveness of the process (reducing the height of the device):

X 4  f Re, , , L ,

(8)

3 Conclusions

Hence,

i  f  X 1 , X 2 , X 3 , X 4   f Re, , , , L.

high foam layers, thin films of the liquid and leads to an increase in the contact surface of the phases and its continuous renewal. Constructive methods will include the usage of mechanisms and contact devices. They contribute to the process of phases’ turbulence and increase the contact surface of phases. It requires combining the technological methods of controlled influence on the structure of flows, creating the necessary conditions for the intensive flow of physical and chemical processes in the working volume of the device in the design of mechanism. Hydrodynamic and constructive methods as components of the subsystem are interconnected and affect both each other and the subsystem. The kinetic coefficient K of the process is determined by the reaction rate and diffusion in the liquid and gas phases. In the processes of mass transfer, the diffusion limits the speed of the process and determines the value of the coefficient K for heterogeneous processes, not related to chemical transformations. The value of K depends on the options of the gas-liquid system’s state, which are sufficiently exposed to managed influence. They are temperature, pressure, the relative velocity of phases, physical properties of substances. Most of these options are functionally connected with the motive force of processes. The degree of influence of these factors essentially depends on the hydrodynamic mode of the apparatus operation. The higher the intensity of the environment’s flow, the less effect proceeds the molecular diffusion on the process compared with the convective, which causes the acceleration of mass transfer processes and the intensification of the gas purification process in general. Therefore, the intensification phase mixing should be considered as potentially promising method of increasing the rate coefficient of the process. The fourth subsystem of factors X4 are the factors of influence on the volume of the apparatus. Reducing the device’s volume takes place due to increasing the gas speed (decreasing of cross-sectional area of the apparatus at a constant flow rate) and the effectiveness of the process (reducing the height of the device).

(9)

Since the hydrodynamic mode of operation of the apparatus affects all components of the process intensification, we will consider the optimization task by operating parameters of the gas cleaning equipment. According to Berdt, Brunstein, Schegolev et al., the hydrodynamic mode of operation of the equipment and its structural design [12, 13] determine the mechanism of the influence of physical factors on mass-exchange and chemical processes in the working volume of the apparatus. Hydrodynamic methods include the operation of equipment in highly turbulent mode at high gas velocities that promotes the grinding of the liquid, the creation of

The problem of improving the environmental security level through the intensification of environmental processes is related to the proper selection and development of high-performance equipment that will improve cleaning efficiency and reduce energy costs of the process. We consider the possibility of optimizing the conditions of conducting environmental protection processes by intensity, as an integral characteristic of the efficiency of the processes carried out for each pollutant. Our conclusions are based on the analysis of the functional dependence of the effectiveness of environmental processes on kinetic characteristics, the mechanism of the interphase surface’s formation, development of driving forces and structural features of the apparatus design.

Journal of Engineering Sciences, Volume 4, Issue 2 (2017), pp. G 12–G 16

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References

1. Rykhter, L. A. (1981). Okhrana vodnoho y vozdushnoho basseina ot vybrosov TES [Protection of water and air basin from emissions of thermal power plants]. Enerhoyzdat, Moscow [in Russian]. 2. Kutovyj, V. O., Konoval’chyk, M. V., Kanyuk, N. P. (2006). Zolovidvaly elektrostancij yak dzherelo zabrudnennya dovkillya [Ash and slug dumps of power plants as a source of environmental pollution] Visti Avtomobil’no-dorozhniogo instytutu, Vol. 1 (2), 90–94 [in Ukrainian]. 3. Krupskaya, L. T., Starozhylov, V. T (2009). Geoekologiya landshaftov v zone vliyaniya teploelektrostancii : monograph [Geoecology of landscapes in zone of thermal power plant influence]. DVGU, Vladivostok, pp. 108 [in Russian]. 4. Cherentsova, A. A. (2012). Otsenka vliyaniya zolootvala Habarovskoy TETs-3 na komponentyi okruzhayuschey sredyi [Assessment of the influence of the ash dump of Khabarovsk CHPP-3 on the components of the environment]. Electronic scientific publication “Uchonyie zametki TOGU”, Part 3, Vol. 1, 29–42 [in Russian]. 5. Barieva, E. R., Korolev, E. A., at al. (2008). Otsenka ekologicheskoy opasnosti zoloshlakovyih othodov Kazanskoy TETs-2 [Assessment of environmental hazard of ash and slug dump of Kazan CHP-2]. Izvestiya vyisshih uchebnyih zavedeniy. Problemyi energetiki, Vol. 5–6, pp. 108–111 [in Russian]. 6. Mylenka, M. M. (2008). Aerotekhnohenne zabrudnennia dovkillia vykydamy Burshtynskoi teploelektrostantsii[Aerotechnogenical pollution of the environment by emissions of Burshtyn thermal power plant]. Suchasni ekolohichni problemy ta molod-IV, Zaporizhzhia, Part V, Vol. 5 [in Ukrainian]. 7. Zvereva, V. P., Krupskaya, L. T. (2012). Otsenka vliyaniya zolootvalov teploelektrostantsiy na ob'ektyi okruzhayuschey sredyi (na yuge Dalnego Vostoka) [Assessment of the impact on environmental objects of ash and slug dumps of thermal power plants (in the south of the Far East)]. Materialy Mezhdunarodnogo Foruma gornyakov-2012, Vol. 1, 154-161 [in Russian]. 8. Belyavskiy, G. A., Varlamov G. B., at al. (2002). Otsenka vozdeystviya objektov energetiki na okruzhayuschuyu sredu [Assessment of the impact on the environment of energy facilities]. HGAGH, pp. 369 [in Russian]. 9. Prybylova, V. M., Zhemerova, V. O., Reshetov, I. K. (2010). Osoblyvosti nakopychennya zabrudnyuvachiv v zoni vplyvu Zmiyevskoyi TES [Features of pollutants accumulation in the zone of influence of the Zmevskaya TPP]. Visnyk Kharkivskogo natsionalnogo universytetu im. V. N. Karazina: Geologiya-geografiya-ekologiya, Vol. 882, 62–67 [in Ukrainian]. 10. DSTU ISO 14001 : 2006. Systemy ekologichnogo keruvannya. Vymogy ta nastanovy shchodo zastosuvannya (ISO 14001 : 2004, IDT) [in Ukrainian]. 11. DSTU ISO 14004 : 2006. Systemy ekologichnogo upravlinnya. Zagal’ni nastanovy shhodo pryncypiv, system ta zasobiv zabezpechennya [Environmental management systems. General guidelines on principles, systems and tools] (ISO 14004 : 2004, IDT) [in Ukrainian]. 12. Brounshteyn, B. I., Schegolev, V. V. (1988). Gidrodinamika, masso- i teploobmen v kolonnyih aparatah [Hydrodynamics, mass and heat transfer in column apparatuses]. Himiya, pp. 336 [in Russian]. 13. Berdt. R., Styuart, V., Laytfut, E. (1974). Yavleniya perenosa [Migration phenomena]. Himiya, pp. 688 [in Russian].

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JOURNAL OF ENGINEERING SCIENCES УРНА ІН

Н РНИХ НАУ УРНА ИН

Н РНЫХ НАУ Web site: http://jes.sumdu.edu.ua

DOI: 10.21272/jes.2017.4(2).g17

Volume 4, Issue 2 (2017) UDC 504.5:502.51(282.03):539.16:622.27(477.6)

Investigation of produced waters radioactivity of oil and gas deposits in the Dnieper-Donets province Plyatsuk L. D., Burla O. A., Ablieieva I. Yu.*, Hurets L. L., Roy I. O. Sumy State University, 2 Rymskogo-Korsakova St., 40007, Sumy, Ukraine Article info: Paper received: The final version of the paper received: Paper accepted online:

*Corresponding Author’s Address: October 10, 2017 November 29, 2017 December 6, 2017

i.ableyeva@ecolog.sumdu.edu.ua

Abstract. The process of radioactive pollution of produced waters, oilfield equipment, oil-contaminated soils and sludge is widely spread and differs within the various oil and gas regions. Formation waters contained radioactive element isotopes become the significant source and cause of elevated level of equivalent dose power and as a consequence, an increase in the incidence among the population. The author's idea is formulation of specific recommendations on the decontamination of the investigated objects by conducting the necessary appropriate experimental studies. The purpose of the article is to determine the content of radionuclides, γ- and α-emitters in technogenic objects of Bugruvate oil and gas fields, and to reveal the relationship with the features of mineralogical composition, geological structure and technological process. The γ-spectrometric analysis was used to determine the radionuclide composition of the natural radiators of the 238U (226Ra, 214Pо, 214Bi) and 232Th (228Ac, 212Pb, 212Вi) series in samples of technological sludge, oil, individual soil samples and water. The content of radionuclides of α-emitters was determined using separate radiochemical techniques. It was investigated that the radioactivity of the formation water is mainly determined by 226Ra and 228Ra and the products of their decay.

Keywords: radioactive pollution, γ- spectrometric analysis, radiochemical analysis, radioactive oilfield equipment, equivalent dose power, sludge decontamination.

1 Introduction Natural waters that have mobile contact in all systems of the earth's crust (with rocks, ores, minerals, soils and living organisms) become carriers of radioactive element isotopes [1–3]. The formation waters of oil deposits contain isotopes of radium: 223Ra, 224Ra, 228Ra and 226Ra, the concentration of the last isotope reaches 103 – 105 Bq/m3, which does not comply with environmental safety standards. Based on the analysis of the content of radium in formation waters, it is determined that the hard waters are enriched with isotopes of this elements, in contrast to soft oil waters that contain no more than 10-12 % Ra. In this connection, the question arose of a deeper study of the causes and sources of enrichment of hard waters with radium and its isotopes – 224Ra and 228Ra. Under natural conditions, the appearance of waters with high radium content is facilitated by the collision of groundwater with uranium ores, or the high mineralization of waters and the presence of alkaline earth metal

chlorides (chloride-sodium-calcium water) in them with low bicarbonate and sulphate content. It has been established [4] that the concentration of radium increases in parallel with the increase in the content Na+, K+, Ca2+, Mg2+, Cl-. The dependence of the content of radium and thorium on the sulfate and carbonate content of waters has a similar nature. With a decrease in the concentrations of SO42- and CO32-, the concentrations of 226Ra and 224 Ra in groundwater increase. It is determined that the ratio between the content of 226Ra and the total mineralization for different stratigraphic complexes varies in the range from 0.01 to 4.6. According to authors [5] equipment in oil fields can contain radioactive accumulations and radioactive sludge that form crusts or deposits. These accumulations are formed as a result of the interaction of equipment with formation water due to changes in temperature, pressure and mineralization, when the water is released to the surface, as well as during the separation of oil from associated water. They are a mixture of carbonate and sulfate

Journal of Engineering Sciences, Volume 4, Issue 3 (2017), pp. G 17–G 21

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minerals, among which barite is found, which easily includes radium into its structure. Studies of the radioactivity of oilfield equipment and contaminated soils in oil fields [6–8] show that the radium waters of oil and gas bearing provinces contain from 1 ∙ 10-9 to 1.2 ∙ 10-8 g/l of radium. Such water, after separating the condensate and methanol, is pumped into the aquifer at a depth of about 3000 m. Fallout with specific activity from 1 to 100 kBq/kg (50–5000 μR/year) is collected and transported to a storage warehouse for slurries, where they are stored in containers. Pump-compressor pipes (PCP) raised from the depths of 2–4 km have an activity of 100 to 6000 μR/h, owing to which they can be attributed to radioactive waste in accordance with modern classification [9]. Apart from the additional costs of cutting and transporting pipes, complex environmental problems arise dealing with the releasing of natural radionuclides into the region environment. At the same time, in terms of its mineralogical composition, radioactive deposits of pipes are rather heterogeneous, depending on the depth of extraction and deposits. Some of the lightly soiled pipes can be deactivated by simple methods and used in the local economy or as scrap metal. The safety of maintenance personnel and the protection of the environment from the uncontrolled spread of radionuclides are the main factors during decontamination. Therefore, decontamination can be carried out using methods that combine a high degree of mechanization of all technological operations, remote control of processes and reliable localization of radionuclides to a limited extent [10, 11]. Different methods of decontaminating equipment and structures using various means, technical devices and special substances are used depending on the characteristics that occur during removing radioactive substances. In connection with this, it is necessary to conduct a study of the radioactive characteristics of formation waters as the main source of contamination of equipment, pipes, and environmental objects. Thus, the aim of this paper is to determine the content of radionuclides, γ- and α-emitters in technogenic objects of Bugruvate oil and gas fields, and to reveal the relationship with the features of mineralogical composition, geological structure and technological process.

2 Methods 2.1

Materials

The measurements of the exposure dose rate and radon concentration in the air at the sites of the Kachanovka pumping station of oil, the Bugruvate deposit, at the temporary radioactive waste storage site were performed during field work. Sampling of technological media and objects was carried out simultaneously with the measurements. Also, the territory of Bugruvate village was tracked, which is located in the zone of influence of the Bugruvate deposit, sampling of natural objects was done. To assess the radioactive effect on personnel, the content of radionuclides in the formation water, oil, various G 18

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sediments and silt taken from the process equipment (pipelines, tanks, settling tanks) was measured. Pollution of the environment was assessed by the content of radionuclides in surface and groundwater, and soil [12]. Samples were taken at different sections of the technological process for the analysis: mineral deposits from the inner surface of the tank (1b), mineral deposits from the inner surface of the separation vessel outlet (2b), bitumen deposits of PCP (3b), mineral-bitumen deposits from the other outlet of the separation tank (4b), salt deposits from the external surface of pumping equipment (5b), mineral deposits from the inner surface of the pipe (6b), degassed water-oil mixture (1n), technological sludge from the bottom of the broken sand trap (1m), sludge from the bottom of the operating sand trap (2m) (see table 1). Table 1 – Basic physical characteristics of samples

Sample number 1b

2b 3b 4b

5b 6b 1n 1m 2m

Physical properties of sediments Deposits of tuberous lamellar dark brown in colour 2–3 mm thick. The colour of the broken plates is black. Rough, easily crushed into powder in a mortar. Plate grey in colour, very dense, brittle, easily crushed into powder. Fatty paste-like mass of black colour with the smell of oil. Mineral-bituminous crustaceans are dark brown in colour. Mechanically brittle, easily kneaded. Strongly smeared. Crystals of salt. For all characteristics there corresponds a sample 2b. Viscous black liquid. Suspension of oil and mineral sludge of black colour. Suspension of oil and mineral sludge of black colour.

For laboratory measurement, 4 soil samples were taken: 1s–4s. Samples of soil were selected on virgin lands. Depth of selection was 5–6 cm. In appearance, the soil can be attributed to chernozem. Samples of formation water were collected at the following points in the process: ─ an oil trap near the village of Kachanivka (sample 1f); ─ input collector Bugruvate sewage pumping station (SPS) (sample 2f); ─ outlet collector Bugruvate SPS (sample 3f). Immediately after the selection, the water samples were clear and no turbidity was observed. After three days in the water samples, a small amount of precipitate of iron hydroxide precipitated, which was filtered out on a paper filter "blue tape". A few days later a similar precipitate again occurred in the samples, which is due to oxidation of bivalent iron to trivalent iron.

2.2

γ- spectrometric analysis

A γ-spectrometric unit EVT consisting of a DGDK100V-3 semiconductor detector, a single-board spectrum analyzer No. 21 and a SELERON 1,2 computer was used for measurements. The relative error in the measurement was not more than 20 %. Exposure time was determined by the radioactivity of the samples – 3 600 s. The measurements were carried out in the standard Dent geometry [13]. The aim of the γ-spectrometric analysis is to determine the radionuclide composition of the natural radiators of the 238U (226Ra, 214Pо, 214Bi) and 232Th (228Ac, 212Pb, 212 Вi) series in samples of technological sludge, oil, individual soil samples and water. To determine the radionuclides 224Ra, 226Ra and 222Rn, a QUANTULUS liquid scintillation spectrometer was used [14].

2.3

Radiochemical analysis

The content of radionuclides of α-emitters was determined using separate radiochemical techniques [15]. Preliminary preparation of sediment, silt and soil samples before radiochemical analysis consisted of the following: 1. Taking samples weighing 1–2 g. 2. Calcination of samples at 500 ° C for 3 hours. 3. Decomposition of samples in mineral acids. The sample 2b was very poorly soluble in such acids as hydrochloric, sulphuric, nitric and hydrofluoric. More complete dissolution was observed after fusion of the sample with potassium hydroxide, but a small residue after dissolving the alloy in hydrochloric acid and evaporation in soda remained. The sample contained little iron. Its chemical composition was mainly determined by sulphates and silicates of alkaline earth metals. Samples 1b, 3b, and 4b were mostly completely dissolved in the 6M solution of hydrochloric acid, but with sediment in solutions of samples 3b and 4b, precipitation of silicic acid after cooling was observed. The basis of the chemical composition is represented by various iron oxides. The principle of radiochemical concentration and uranium extraction is based on its sorption on the Dowex-1 anion in a hydrochloric acid medium, and thorium in a nitrate medium [16]. Samples to measure the activity of uranium and thorium were prepared by an electrochemical method. To determine the chemical composition of uranium, a radioactive label 232U was used. The chemical composition of thorium was estimated from preliminary analyses of identical samples with the introduced reference activity and was equal to 70 %. The α-activity was measured on an ORTEC α-spectrometer. The sensitivity of the techniques for these radionuclides is 0.001 Bq per sample.

3 Results The results of γ-spectrometric analysis of radionuclide activity in the investigated process sediments, sludge and oil are given in Table 2. Table 2 – Results of γ-spectrometric measurements of radionuclide activity in process sediments, sludge and oil

Specific activity of radionuclides, kBq/kg

Sample

In this paper, the specific radioactivity of water in the river Khukhra and in some sources of drinking water – wells were measured. Because of the low content of radionuclides, their determination in these waters was carried out by radiochemical methods after preliminary concentration by evaporation.

226

214

16.2 1270 0.85 47.5 0.105 – 0.012 3.87 0.36

16.2 1270 0.85 47.5 0.106 – – 3.8 0.36

1b 2b 3b 4b 5b 6b 1n 1m 2m

Pо

Вi

214

228

212

16.2 1270 0.85 0.87 47.5 0.107 – 3.8 0.373

9.83 3.95 0.38 4.93 0.108 – 0.003 1.547 0.175

16.9 1350 0.85 50.2 0.102 – 0.012 3.88 0.34

212

1.73 1.85 0.5 0.07 – – 1.07 0.113

The results for α-emitted radionuclides in the investigated sediments and sludge are given in Table 3. Table 3 – Content of α-emitted radionuclides in sediments and sludge determined by radiochemical methods Sample

Specific activity of radionuclides, Bq/kg 234

238

228

232

3.51±0.8

2.85±1.1

290.1±18

<1.0

7.58±1.1

2.97±1.1

643.2±65

<1.0

0.98±0.6

0.77±0.3

364±36

<1.0

2.97±1.1

2.50±1.1

1570±160

<1.0

8.50±1.2

8.90±1.2

63±6.5

<1.0

Determination of activity of radionuclides in soil samples was carried out according to the methods of analysis of deposits in technological processes. Figure 1 shows the results of γ-spectrometric measurements and radiochemical analysis.

Bq/kg

35 25 15 5

226 Ra 212 Ві 212 Pb 228 Ас 214 Ві 214 Рb 232 Th 228Th 230Th 234 U

Figure 1 – Radionuclide content in soil samples

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The results of analyzes (fig. 1) show that the abnormally high content of any radionuclide caused by technogenic factors is not observed in soil samples. The content of radionuclides in the selected samples of the soil does not differ from the average values characterized for the given area. There is a discrepancy between the 228Th content calculated from γ-spectrometric measurements of 228 Ac and the results of radiochemical analyzes. The results of analyzes of γ-spectrometric measurements are approximately one and a half to two times higher than the results of radiochemical analyzes using α-spectrometric measurements. Formation water is a highly saline solution that separates from oil after it is lifted to the surface. The salt composition of the reservoir water contains mainly sodium chlorides with a concentration of 100–160 g/dm3. As a result of the impact on the mineral deposits of the deposit, water leaches not only the elements of minerals (iron, aluminum, manganese, etc.), but radionuclides, including daughter radionuclides of the thorium and uranium series. Further, during the processing of the oilwater mixture, precipitation and concentration of stable elements and radionuclides occur on the process equipment. Thus, the formation water is the main supplier of radioactive elements to the surface; therefore it is necessary to introduce a control over the content of radionuclides in them. The results of radionuclides content in water are given in Table 4. Table 4 – Content of radionuclides in produced waters Sample

Specific activity of radionuclides, Bq/dm3 224

226

222

228

1.57±0.31

27.4±4.8

16.87

3.20±0.47

3.98±1.1

28.8±5.9

19.45

5.38±0.8

5.51±1.1

39.8±7.8

19.77

5.57±0.83

230

Th 0.058±0.02

232

Th <0.001

234

238 U U 0.010±0.002 0.007±0.002

0.19±0.02

<0.001

0.013±0.003 0.006±0.003

0.068±0.02

<0.001

0.012±0.03

0.005±0.003

From the results of Table 4 it can be seen that the radioactivity of the formation water is mainly determined by 226 Ra and 228Ra and the products of their decay. This is due to the high leaching power of alkaline earth elements with non-sulfate chloride brines. Produced water contains a very small amount of maternal radionuclides of thorium and uranium, in particular 0.005–0.007 Bq/dm3 of 238U and 0.01–0.015 of 234U. From a geological point of view, it can be concluded that the presence of these elements in rocks contained in oil fields has a subordinate nature without the formation of intrinsic minerals in these rocks.

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4 Discussion The waters of the oil and gas bearing region of the Dnieper-Donets province are compositionally classified as chloride-sodium-calcium, which is a prerequisite for an increased level of radioactivity. This is because the high mineralization of water and the content of chlorides of alkaline earth metals in it, on the one hand, reduces the adsorption of radium, and on the other hand it facilitates the processes of cation exchange and, thereby, the increase in the level of leaching of radium from rocks. A study of the radiation situation within the DnieperDonets cavity showed the problem of contamination of industrial equipment with natural radionuclides (NRN) in all oil-producing enterprises: Chernigivnaftogaz, Poltavanaftogaz, Okhtyrkanaftogaz and the territories of oil and gas refineries. Maximum levels of the equivalent dose power (EDP) from industrial equipment up to 60 μSv/h (6.0·103 μR/h) belong to the production of Okhtyrkanaftogaz. The equivalent dose power for the first two enterprises was at the level of 10 μSv/h (1.0∙102 μR/h). However, from the variety of contaminated equipment, it is possible to single out a part of PCP with high EDP values up to 6 000 μR/h. The activity of these pipes is associated with the radio-borate, which is part of the complex hydrothermal complex. Lead glance (PbS) and native nickel are laid directly on the metal pipes. At the same time, the mineral mass of galena and nickel is armored by a layer (2–4 mm) of radiobarite. The presented hydrothermal complex of minerals is firmly connected with the metal of pipes and is practically not subject to changes in the investigated complex of chemical and physical influences. Industrial equipment of this group is recommended for disposal taking into account the high radioactivity and chemical stability of mineral neoplasms. The maximum total activity of 226Ra on the equipment walls does not exceed 100 GBq. The rate of emanation of mineral formations can be taken as 2.3∙10–6 %/s or 2 300 Bq/s. The maximum content of 226Ra in radioactive sludge is 4 000 Bq/kg. The maximum activity of 226Ra on sites is about 1.63 ∙ 109 Bq under the condition of one year’s accumulation time. The approximate rate of radon emanation from slurries is 8.2∙10-6%/s. The radon exhalation from the desiccation site is 130 Bq/s or 4 GBq/year. The outflow will be formed almost at ground level. The total release of radon as a result of production activities with the site of the Bugruvate deposit will not exceed 730 Bq/s. Decontamination of slurries aimed at reducing the formation of radioactive sludge in reservoirs of formation water, is recommended to carry out by changing the pH of the produced water. For this, 1 l of HCl per 1 m3 of produced water is added, which provides a pH value at a level of 2 units. The slurry solution is settled for 1 month. The permissible level of radioactivity of the slurry is 9 kBq/kg, after which the slurry is mixed with finely dispersed sand in a mixer with a proportion of 1:5 and is subsequently used in road construction.

5 Conclusions The radiation effect of the Bugruvate oil-producing complex on the environment is mainly due to the removal of 238U decay products from the industrial territory. Isotopes 226Ra, 222Rn, 210Pb, and 210Ро are the main doseforming radionuclides when exposed to the population. The total amount of radon released into the environment will be determined by two aggregated sources of emissions. The first is the isolation, impregnation through the breathing valves of the systems, flares of residual gas combustion, leakiness of the armature, flanges in the entire process cycle of oil separation and treatment of formation water. This emission source has a relatively stable release rate of about 200 Bq/s at a uniform production capacity of the field. As the equipment becomes contaminated, this component of the radon emission can increase to 600 Bq/s. The second is radioactive gas emissions in the area of drying the sediment from the sludge. Here, the volumes of emissions and, at the same time, the outflows will increase as

the radioactive sediment accumulates up to 130 Bq/s and decrease stepwise as the next consignment is transported to the disposal site. With conservative estimates of the equivalent dose of external γ-radiation, the total specific activity of 226Ra and 228Ra should be multiplied by a factor of 0.02 [bp/(cm2·min)] / [Bq/kg] to determine the electrons fluxes from the objects of Okhtyrka oil and gas production department (OGPD) that are contaminated by the decay products of the radium radionuclide isotopes. Usage of the emanation factor for radon isotopes of 1 % for dense sediments and 4 % for wet dispersions of mineral precipitation can be recommended to determine the concentration of radon decay products in closed reservoir facilities in the oil fields of the Okhtyrka OGPD during dose estimates. The emanation rate is 2.3∙10–6 %/s and 8.2∙10–6 %/s for sediments and slimes, respectively (the percentages are taken from the total activity of the parent radium in the substance that emits emanation).

References 1. Botezatu, E., & Grecea, C. (2004). Radiological impact assessment on behalf of oil/gas industry. The journal of preventive medicine, Vol. 12, Issue 1, 16–21. 2. Bakr, W. F. (2010). Assessment of the radiological impact of oil refining industry, Journal of Environmental Radioactivity, Vol. 101, 237–243. 3. Dinh Chau, N. et.al (2011). Natural radioactivity in groundwater-a review. Isotopes in Environmental and Health Studies, Vol. 47, Issue 4, 415–437. 4. Smith, K. P. (2002). An Overwiev of Naturally Occurring Radioactive Materials (NORM) in the Petroleum Industry. ANL/EAIS7 Report, Argonne, Illinois. 5. White, G. J., & Rood, A. S. (2001). Radon emanation from NORM-contaminated pipe scale and soil at petroleum industry sites. Journal of Environmental Radioactivity, Vol. 54, 401–413. 6. Godoy, J. M., & Cruz, R. P. (2003). 226Ra and 228Ra in scale and sludge samples and their correlation with the chemical composition. Journal of Environmental Radioactivity, Vol. 70, 199–206. 7. Hamlat, M. S., Djeffal, S., & Kadi, H. (2001). Assessment of radiation exposures from naturally occurring radioactive materials in the oil and gas industry. Applied Radiation and Isotopes, Vol. 55, 141–146. 8. Ceccarello, S., Black, S., Read, D., & Hodson, M. E. (2004). Industrial radioactive barite scale: suppression of radium uptake by introduction of competing ions. Minerals Engineering, Vol. 17, 323–330. 9. Rich, A. L., & Crosby, E. C. (2013). Analysis of Reserve Pit Sludge from Unconventional Natural Gas Hydraulic Fracturing and Drilling Operations for the Presence of Technologically Enhanced Naturally Occurring Radioactive Material (TENORM). New Solutions, Vol. 23, Issue 1, 117–135. 10. Brown, V. J. (2014). Radionuclides in Fracking Wastewater: Managing a Toxic Blend. Environmental Health Perspectives, Vol. 122, Issue 2, A51–A55. 11. Nelson, A. W., Johns, A. W., et al. (2016). Partitioning of Naturally-Occurring radionuclides (NORM) in Marcellus Shale produced fluids influenced by chemical matrix. Environmental Science: Processes & Impacts, Vol. 18, 456. 12. Washington, D. C. (2006). Radioactive Waste from Oil and Gas Drilling, EPA 402-F-06-038. Retrieved from http://www.epa.gov/radtown/docs/drilling-waste.pdf. 13. Birchall, A., Puncher, M., et al. (2003). IMBA expert(r): Internal dosimetry made simple. Radiation Protection Dosimetry, Vol. 105, 421–425. 14. Maxwell, S. L., III; Culligan, B. K., Warren, R. A., & McAlister, D. R. (2016). Rapid method for the determination of 226Ra in hydraulic fracturing wastewater samples. Journal of Radioanalytical and Nuclear Chemistry, Vol. 309, 1333–1340. 15. Birchall, A., Puncher, M., et al. (2006). IMBA Professional Plus: a flexible approach to internal dosimetry. Radiation Protection Dosimetry, Vol. 125, 194–197. 16. Eitrheim, E. S., May, D., Forbes, T. Z., & Nelson, A. W. (2016). Disequilibrium of Naturally Occurring Radioactive Materials (NORM) in Drill Cuttings from a Horizontal Drilling Operation. Environmental Science & Technology Letters,Vol. 3, 425–429.

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Н РНЫХ НАУ Web site: http://jes.sumdu.edu.ua Volume 4, Issue 2 (2017)

Technical higher education in Slovakia was based on the first technical college – famous Mining Academy. Austro-Hungarian monarch Maria Theresa decided to establish the Mining Academy in Banská Štiavnica on December 13, 1762. It was the first Polytechnic in the world. Teaching started in September 1764, when professor of chemistry, mineralogy and metallurgy Mikuláš Jacquin began to lecture. In the following year, the Department of Mathematics and Mechanics was founded, and it was led by the Jesuit Mikuláš Poda. The school received a definitive form by decree of April 14, 1770 and also received the official name Mining Academy. At the same time, a study plan was issued. The study lasted two years, it was free and had the character of a university study. Graduates went to compulsory practice after graduation, which ended with a practical exam and diploma theses. Professors also worked scientifically. Mining Academy in Banská Štiavnica used modern and advanced teaching methods. It soon gained global reputation especially by combining theory with practice and became a model for Polytechnic throughout Europe, for example the famous École Polytechnique in Paris. Textbooks were written in Latin and German. The complete library of the school was moved to the University of Miskolc. The movement for founding a Polytechnic in Slovakia was established in 1919. It was based on pre-war intentions for transformation of Košice academy to the Polytechnic. The organizers of the movement were led by professor of engineering in Brno – prof. Ing. Michal Ursiny. The movement gradually got into awareness of the government institutions and this dream took place after twenty years. On June 25, 1937, the National Assembly adopted Act no. 170 on the approval of the Polytechnic in Košice and the 1938/1939 was the first academic year. On August 4, 1938, the first session of the Scientific Council took place, which appointed the academic staff and prof. Mgr. Juraj Hronec, DrSc. was elected as the first rector. The political-economic situation, national unrests and power ambitions in Europe in the 1930s brought Central Europe to Munich and the Vienna arbitration in November 1938. The events affected the Polytechnic in Košice, which had to move to Prešov. Later, it moved to Martin, where it acted until December 5, 1938. Then, according to Act no. 108 of July 25, 1939 it was relocated to Bratislava as Slovak University of Technology. The next stage in the development of higher education in Košice was more successful. Government Regulation no. 30/1952 Coll. about the establishment of the Polytechnic in Košice the school consisted of the Faculty of Heavy Engineering, the Faculty of Mining and the Faculty of Metallurgy. In October 1952, the Polytechnic was inaugurated. The government has appointed the first rector prof. Ing. František Kámen, CSc. 15 departments, 69 teachers and 8 administrative staff were at that time at the Polytechnic. Since 1 April 1991, the Polytechnic has been renamed to the Technical University of Košice by Act No. 94 on the change of name from the Polytechnic of Košice to the Technical University of Košice dated 13 February 1991. At present there are 9 faculties at the Technical university. The Faculty of Manufacturing Technologies with the seat in Prešov, Technical university of Košice. was formed as the eighth. Deans of the Faculty of Manufacturing Technologies with a seat in Prešov of Technical University of Košice Dr. h.c. prof. Ing. Karol Vasilko, prof. Ing. Slavko Pavlenko, DrSc. dekan, CSc. dekan, Dean 1993 – 1998. Dean 1999 – 2004.

prof. Ing. Jozef Novák-Marcinčin, PhD. dekan, Dean 2005 – 2012.

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prof. Ing. Jozef Zajac, Dr. h. c., CSc. dekan, Dean 2013 – present.

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DOI: 10.21272/jes.2017.4(2).h1

Volume 4, Issue 2 (2017) UDC 004.42

Model of the management program for a means complex of the design works automation as a finite-state automaton Zakharchenko V. P.*, Marchenko А. V., Nenia V. H. Sumy State University, 2 Rymskogo-Korsakova St., 40007, Sumy, Ukraine Article info: Paper received: The final version of the paper received: Paper accepted online:

*Corresponding Author’s Address: November 11, 2017 November 28, 2017 December 1, 2017

victoriait@ukr.net

Abstract. For software development it is necessary to have its mathematical model. It is established that for a means complex of the design works automation a model of a finite automaton is the best choice. The automatic machine has been chosen with a single feedback state, which asynchronously initiates the execution of design procedures, on which there are Terms of References. For this an additional requested automaton is used. This automaton implements the selection of design work according to a status of the initiated design procedure. Commands of designers also are processed by a separate automaton. Situations arising in the automated design process and are associated with designers’ commands, are divided into five groups. Keywords: program model, finite-state automaton, automation means, design works.

1 Introduction Design takes the important place in the life cycle of technical objects. It is so because at this stage efficient, reliable and durable their functioning is provided. Fast and ecological withdrawal of technical objects from the operation also takes place at this stage. Manufacturing of technical objects continues to grow nowadays. There is a feature of modern phase of its development which recently takes place [1]. It means that the volume of design works increases in ten times every ten years. At the same time, labor productivity in manufacturing grows up to 1000 %, while in design and construction it grows only up to 20 %. The overcoming of this contradiction by means of application the systems of design works automation (SDWA) has led to success.

2 Statement of the problem From the beginning of systems for design works (SDWA) automation the algorithms, which were adapted to specific objects, were offered for computerized execution of design procedures. The work [2] has generalized experience of the initial stage of SDWA development.

There the proposed algorithm of design for a robotic complex has been presented. It is clear, that development and improvement of software for design in the conditions of the progressing development of element base in the presence of a rigid design algorithm is almost unpromising thing. This confirms the historical experience of development of systems for design works automation, and actually its absence. Launching the logic schemes of design was the next step [3]. Introduction of a logical description of the design process became an important stage, the essence of which is to separate the description of the design process from the software of its implementation. The lack of a formal description of design processes and appropriate information technologies have not given practical results for the last four decades. Substantially this has been promoted by commercialization of software and significant “advertising pressure”. Under its influence, separate decisions of computerization the constructing process without design, without complex approach to the tasks solution inherent to a design stage as one of the most important stages in life cycle of a technical object have become widespread. The biggest shortcoming is the lack of a computerization for the design process management. Methodological

Journal of Engineering Sciences, Volume 4, Issue 2 (2017), pp. H 1–H 8

incorrect definition of the design works automation allows managers of industrial enterprises and design organizations to report about essential level of the design works automation. Although design automation itself is practically absent, and its mechanization is at extremely low level. Therefore, the topical problem is to develop the scientific and methodical basis of mechanization and automation of design works in general and to develop models of the software which are considered in this paper.

3 Related works

It is necessary to develop the program according to the type of solvable tasks. Nowadays it is steady to divide programs into two types [4]. Programs which transform the data (transforming programs) belong to the first type. Programs which react to actions of the user (responding programs) belong to the second type. In the pure form, such programs are encountered extremely rarely. Usually there are programs of the combined type. Reference of the program to a concrete type is defined by the prevailing part of the performed functions. The most successful programs developments essentially take into account the peculiarities of their functioning and use appropriate formalism (theory, models, methods and algorithms). The programs complex of systems for design works automation is developed as a combined complex with a clear distribution of performed functions between programs. Programs which are used in the design procedures are developed as transforming programs. They read the output data from files, perform the corresponding design calculation and write down results in the certain file. Programs, by means of which the design process and its management are organized, belong to type of responding programs. Exactly the last ones as more complex programs are considered in this work. The first from eleven fragments of a flowchart of the technical object automated design is presented in Figure 1 from the work [2]. The analysis shows that this fragment contains four from forty states of the decision-making program regarding the directions of the continuation of the design. The states of control for reading and writing the design data are added to the mentioned states (ten cases on a fragment). Therefore, it is clear that the main program of the design process management has to belong to a type of the responding programs. According to the chosen type of programs, we use the corresponding model of the program, which represents the main software as a state machine [5]. In native practice it is accepted to call such machine as a finite-state automaton [6]. The theory of finite-state machines considers several problems, implementation of which guarantees that the proposed solution will match the necessary requirements in the best way. Firstly, the automaton must be minimal. The minimal automaton is

Computational Engineering

an automatic machine which has the smallest possible quantity of states and implements the set function of outputs. For any finite-state automaton the equivalent to it a finite-state automaton with the smallest number of states can be constructed [7]. The minimality of the automaton provides the minimal cost and the maximum reliability of work. Secondly, the automaton has to give an opportunity of the transition into any set state. This requirement provides the implementation of functional requirements completeness. The authorsâ&#x20AC;&#x2122; choice of a finite-state automaton as a model of software for automated design management is supported by the current tendency to develop the controlling programs of various directions [8â&#x20AC;&#x201C;10]. Application the modelling of the responding programs in the form of finite-state automatons continues to be investigated in various directions. They have been analysed below. The work [11] is devoted to the development of logical control programs models and corresponding formalism. The finite-state discrete automaton as a management program model is described by directed graphs as the use of a large number of the machine states is supposed. The problem of parallel processes management is solved by the decomposition into several graphs. The problem of coordination connected with the use of the synchronism concept is solved separately. In the work [12] the synthesis of control systems, which use the microcontrollers, is presented. The offered method of automatic programming is considered below. This method is based on the formation of the program model according to the structural scheme of a control automaton new type. The new structural software model differs by introducing the multiplexer for selection one logical condition according to the code of the automaton state. This condition is checked at each step of the program model work. The offered method is focused on the structural organization of automatons with an input multiplexer. The result of this variant of automatic programming are high-speed programs with a minimal number of commands of the program code. The problem of ambiguities elimination during the work of a finite-state automaton within the creation of control program systems is considered in work [13]. The structural scheme of the finite-state automaton model was created by the authors. It was done by taking into account the waiting time for the performance of functions and the result of their performance, the counting of the events number and stacks of states. It is concluded that the use of a finite-state automaton in the field of the program systems allows to determine the behavior of the program, to minimize the number of errors in the program logic and formalize the development process. The authors found it convenient to use the index-matrix approach to solve the problem of changing the automaton states.

Figure1 â&#x20AC;&#x201C; Fragment of the automated design flowchart

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In the work [14] the models of programs for management of the parallel and distributed processes are presented by three groups: the generalized models, the models of data flows and the models of parallel processes with the interaction between them. Preference is given to models of the third group. At the same time it is specified their shortcomings. For example, the models do not allow a possibility of asynchronous interaction between processes (only via the rendezvous mechanism) and do not contain mechanisms for the creation of flexible templates of management modules. A multi-level model of distributed programs has been offered. It consists of the level of module templates (the highest level), the levels of distributed and embedded modules, and the structural and register level (the lowest level). Along with this, it is recognized that such model can be suitable for systems with a predetermined set of tasks. However, it is not suitable for the models of programs for design works automation because a means complex of the design works automation has to be constantly extended and be improved [3]. Models of programs can be built both on the basis of one finite-state automaton, and on the basis of their combinations. So in the work [15] the model on the basis of parallel automatic machines or one automatic machine, which has a set of descriptions of simultaneous partial states, is investigated. On the basis of sets of the atomic, partial or full state of the parallel automaton and parallel inputs the parallel functions of transitions and parallel outputs, which are set by matrixes of transitions and outputs, are defined. This way makes it possible to implement three types of the processes interaction: synchronous, ordinary and mixed. Conditions for the transformation of a parallel automaton into parallel-sequential compositions of simple automatons also have been formed. Additionally to the peer automaton there is a possibility to create the hierarchical structures of automatic machines. So in the work [16] the set-theoretic description of such model has been investigated. There is a main automaton on top of the hierarchy. Embedded automatic machines perform subordinate roles and are located below in the hierarchical structure. Information communications on reception a condition of the management object and on giving to it certain management commands take place at all hierarchical levels of the structure of the management automaton. The efficiency of the proposed hierarchical model has been demonstrated both on Moore machines and on Mealy machines. In addition to hierarchical, the models use regular structures in the form of cellular [17] and multitape structures [18]. Considerable attention continues to be paid to the minimization of finite-state automatons taking into account previously adduced arguments and which are supported by other researchers definitely. In the work [19] the solution of a problem of minimization for the automatic machine, behavior of which depends on the time when the

Computational Engineering

input command or event occurs, and to which the automaton responds, is considered. It is also shown that there is a single minimal form for a fully determined automaton with temporary restrictions. The algorithm of minimization for a fully determined automatic machine with temporary restrictions is offered. It has been proposed on the basis of creation the splittings according to such equivalent states, at which if there is the identical number of identical commands at the outputs, we will have the identical results. The algorithms needed simultaneously for solution of two problems of minimization of nondeterministic finitestate automatons, vertex and arc ones, are given in the work [20]. Taking into account the fact that the arcs correspond to the functions performed by the automatic machine, the reduction of the arcs number is not acceptable. It is so because the object that simulates such automaton will not conform to the specified requirements. A useful opportunity is the simultaneous construction of the functions for the states markup. Fuzzy machines are considered in the work [20] from the position of using the minimax criterion for evaluating their functioning if there are fuzzy commands on the input. The results of this work can be used for processing the dialogue of designers and constructors based on the elements of their professional communication language.

4 Purpose of the work The purpose of the work is to develop a model of the functioning of the system software for a means complex for the design works automation. The research object is the organization of the technical objects design process. The research subject is the model of program implementation of the design process organization.

5 Research results The process of the functioning the management program of a means complex for the design works automation is the basis of the software tools functioning. It is impossible in advance to predict all possible aspects, structure and types of design works if it is necessary to solve new tasks [3]. Despite this still there is a need to develop and use the automation means. Therefore, it is expedient to solve this contradiction by using a different approach to the design of a finite-state automaton as a model of means for design works automation instead of its synthesis taking into account all performed functions and transitions into all necessary states. To implement this gained experience in theory of inventive problem solving is used, for example [21]. According to provisions of this theory the proposed solution is better when it gets closer to the ideal end result. At the same time the ideal end result is understood as that one, at which the required function, is performed and the object itself, which performs this function, is absent. It determines the

provision for the development of the design object structure of the minimum complexity. For implementation of this provision the following consecutive algorithm of development is used: 1) to offer the functional model of the investigated object; 2) to choose an element, which implements the functional model; 3) to improve an element for the implementation of a full design process; 4) to supplement the element with necessary components for the information technology implementation. Under the condition of self-management and usage of own mechanisms of actions performance, the functional scheme of the work of a means complex for the design works automation takes the form, which is shown in Figure 2, where ToR – Terms of Reference.

Figure 2 – Context diagram of the functioning of a means complex for the design works automation This diagram should be considered as a model of the ideal tool, which in one step allows to perform the design in accordance with the requirements of Term of Reference (ToR).

Due to the design of a new mechanical engineering object (new structure and performed functions) every time, it is impossible in advance to predict all possible logic design schemes and corresponding processes of the work of the design management subsystem. It is also impossible to offer the fixed order of the design and its program implementation even for one object, its components of different degree of complexity and various structures of the construction, which are unknown in advance. At the same time it is obvious that the management subsystem must pass through a certain number of fixed states, in which the analysis of the current situation is carried out. Also the corresponding decisions according to ways of the continuation of any process, both the manufacturing design process and the auxiliary process (code conversion, reformatting, etc.) are made. Such behavior of a subsystem is implemented in the models of finite-state automatons. They are offered for use as information technology of processing of the current data both about the mechanical engineering objects design and about processes of its formation and interaction of the components of human, information and software complexes. According to the accepted technology for the finitestate machines design [22, 23], it has been carried out the decomposition of the model from the Figure 2, which takes the following form (Fig. 3), where ToRі – the state of the design object structure; SDPі – the state of the corresponding design process in accordance with the implementation of manufacturing tasks.

Figure 3 – Decomposition of the generalized scheme of the finite-state automaton This decomposition considers that a finite-state machine changes the waiting state if there is any change in the state of the design process and the change of the state of arbitrary components in the design object structure. The automaton works asynchronously according to the cyclic scheme with a feedback. For the transitions performance (actions for design and management) additional automatic machines for the performance of own transitions are involved. Such technique excludes a problem of the state uncertainty: a possibility of performance of all transitions and

going through all necessary states. To exclude the need to remember all previous commands and states, the states vectors of the design object structure and the states of the design processes are introduced. The model of a finite-state automaton, which processes the states of projects, has its structure shown in Figure 4. The model of a finite-state automaton, which processes the actions of designers according to the implementation of design processes, is presented in Figure 5.

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Figure 4 â&#x20AC;&#x201C; Model of the finite-state automaton which processes the projects formation

Computational Engineering

Figure 5 â&#x20AC;&#x201C; Model of the finite-state automaton which processes the commands of designers For these models states are marked as ovals, transitions (performed actions) as lines. In inscriptions conditions are indicated firstly. The next there are actions performed according to them. In the work [24] it is pointed out the complexity of application the model of the finite-state automaton to the distributed computer systems. The complexity exists because of the practical impossibility of fixation the structure of all its components. The use of such argument is justified in a case of the parallel performance of interconnected, and as a result controlled, calculations. If the asynchronous performance of the independent design works is applied to this case, the given argument is not significant. In this situation the state of each implemented projects, which is fixed in vectors sets of a state of each design procedure and each design object, is essential. The offered linear sequence of states and actions guarantees performance of all actions and going through all states. The single-step type of the automatic machines work provides uniformity of their functioning and a possibility of their application to the design of objects with any structure.

6 Conclusions The process of functioning the management program of a means complex for design works automation in the form of a finite-state automaton was presented during the performance of this research. The uniform description for functioning of the software means for the organization of automated design and its management was achieved.

7 Further work If the mechanism of functioning of the software means for the organization of automated design and its management is in the presence, it demands the development the uniform information description of assignments for design.

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References

1. Prohorov, A. F. (1987). Konstruktor i EVM. Mashinostroenie [in Russian]. 2. Budya, A. P., Kononuk, A. E., et. al. (1988). Spravochnik po SAPR. Tehnika [in Russian]. 3. Zhuk, K. D. & Timchenko, A. A. (1983). Postroenie sovremennyh system avtomatizacii proektirovaniya. Naukova dumka [in Russian]. 4. Karpov, U. G. (2010). Model cheking. Verifikacija parallel'nyh i raspredelennyh programmnyh system. BHV-Peterburg [in Russian]. 5. Fedotov, I. E. (2012). Modeli parallel’nogo programmirovaniy. Solon-Press [in Russian]. 6. Amosov, N. M. & Artemenko I. A. (1974). Jenciklopedija kibernetiki. Ukr.-sov. encikl. [in Russian]. 7. Gill, A. (1966). Vvedenie v teoriyu konechnuh avtomatov. Nauka [in Russian]. 8. Zaboleeva-Zotova, A. V. & Orlova, U. A. (2010). Avtomatizaciya nachal’nuh etapov proektirovaniya programmnogo obespecheniya. Izvestija Volgogradskogo gosudarstvennogo tehnicheskogo universiteta, Vol. 6 (8), 121–124 [in Russian]. 9. Filatov, V. A. & Kozyr’, O. F. (2013). Model’ povedeniya avtonomnogo scenariya v zadachah upravleniya raspredel’onnymi informacionnymi resursami. Inzhenernyj vestnik Dona, Vol. 26, No. 3 (26), 24–36 [in Russian]. 10. Kozachenko, V. F. (2010). Effektivnyj metod programmnoj realizacii diskretnyh upravljajushhih avtomatov vo vstroennyh sistemah upravlenija [in Russian]. 11. Novozhilov, B. M. (2015). Primenenie grafov v razrabotke programm dlja PLK. Vol. 2, p. 6 [in Russian]. 12. Muchopad, U. F. & Muchopad, A.U. (2014). Analiz i sintez upravljajushhih avtomatov slozhnyh tehnicheskih sistem. XII Vserossijskoe soveshhanie po problemam upravlenija VSPU-2014, pp.7295–7306 [in Russian]. 13. Smirnova, N. V. & Smirnov, V. V. (2014). Primenenie teorii konechnyh avtomatov v razrabotke programmnyh sistem. Tehnіka v sіl's'kogospodars'komu virobnictvі, galuzeve mashinobuduvannja, avtomatizacіja, Vol. 27, 316–320 [in Russian]. 14. Bolshakov, O. S., Petrov, A.V., et. al. (2015). Model' raspredelennyh programm dlja vstraivaemyh sistem. Vestnik Rybinskoj gosudarstvennoj aviacionnoj tehnologicheskoj akademii im. P.A. Solovyova, Vol. 1 (32), 165–171 [in Russian]. 15. Vorobev, V. A. (2006). Model’ parallel’nogo avtomata. Avtometrija, Vol. 42 (3), 85–93 [in Russian]. 16. Kyzmin, E. V. (2006). Ierarhicheskaja model’ avtomatnyh programm. Modelirovanie i analiz informacionnyh sistem, Vol. 13 (1), 27–34 [in Russian]. 17. Schiff, J. L. (2011). Cellular automata: a discrete view of the world. John Wiley & Sons. 18. Furia, C. A. (2012). A survey of multi-tape automata. arXiv preprint, arXiv:1205.0178. 19. Tvardovskii, A. S. & Evtychenko, N. V. (2014). K minimizacii avtomatov s vremennymi ogranichenijami. Vestnik Tomskogo gosudarstvennogo universiteta. Upravlenie, vychislitel'naja tehnika i informatika, Vol. 4, 77–83 [in Russian]. 20. Melnikov, B. F. & Melnikova, A. A. (2011). Mnogoaspektnaja minimizacija nedeterminirovannyh konechnyh avtomatov. Chast’ І: Vspomogatel’nye fakty i algoritmy. Izvestija vysshih uchebnyh zavedenij. Povolzhskij region. Fiziko-matematicheskie nauki. Matematika, Vol. 4 (20), 59–69 [in Russian]. 21. Orlov, M. A. (2006). Osnovy klassicheskoj TRIZ. Prakticheskoe rukovodstvo dlja izobretatel’nogo myshlenija. Solon-Press [in Russian]. 22. Lee, E. A. & Varaiya, P. (2007). Structure and Interpretation of signals and Systems. Lee & Seshia. 23. Karpov, Y. G. (2003). Teorija avtomatov. Piter [in Russian]. 24. Cheremisinov, D. I. (2011). Proektirovanie i analiz parallelizma v processah i programmah. Belarusskaja nauka [in Russian].

Computational Engineering

JOURNAL OF ENGINEERING SCIENCES УРНА ІН

Н РНИХ НАУ УРНА ИН

Н РНЫХ НАУ Web site: http://jes.sumdu.edu.ua

DOI: 10.21272/jes.2017.4(2).h9

Volume 4, Issue 2 (2017) UDC 004.42

Visual object-oriented technology and case-tools of developing the Internet / Intranet-oriented training courses Salaimeh S. A.*, Hjouj А. A. Aqaba University of Technology, 79 Wasti al-Tal St., 11191, Amman, Jordan Article info: Paper received: The final version of the paper received: Paper accepted online:

*Corresponding Author’s Address: November 20, 2017 December 1, 2017 December 3, 2017

safwan670@yahoo.com

Abstract. New information technologies, modern computers, LAN, WAN networks enable us to modernize the whole education system. One of the most perspective ways of the modern educational system’s development is online education. The questions of developing the visual instrumental system PIECE designed to automate processes of creation the cross- platform hypermedia training and controlling course (HTCC) are viewed in this paper. Keywords: platform, training course, hypermedia, tools, educational system, modernization.

1 Introduction

2 Methods

New information technologies, modern computers, LAN, WAN networks enable us to modernize the whole education system. One of the most perspective ways of the modern educational system’s development is online education. Many major international corporations, such as oracle, Microsoft, etc. have their training centers all over the world. They enable to provide online education via internet and e-mail. In the most of highly developed countries the great deal if instruction by correspondence is based on the online training. In Jordan online education is in the first stages. Now the main obstacles are the lack of necessary laws and highly developed state infrastructure. In order to subdue the difficulties of crisis in modern education service, now the most perspective trends of scientific exploration and practical works is to create methods, tools and information technologies, providing effective and high grade online education, electronic training information interchange, interactive computer – based both control and self- control of student’s knowledge [1, 2].

2.1

The tools of online education

Online education is design to enhance to the efficiency of providing the education services, using the modern computer equipment telecommunication systems. New information technologies and tools of its providing. There are some base classes of the modern tools used for enhance the efficacy of online education, such as: ─ ─ ─ ─ ─ ─ ─ ─

electronic publications; online practical and laboratory works; computer – based training systems with remote access; online database and knowledge - base; electronic libraries with remote access; audio and video information training stuff; geo information teaching systems; tools for creation and filling them with training information.

2.2 Technology of development training system PIECE The questions of developing the visual instrumental system PIECE designed to automate processes of creation the cross- platform hypermedia training and controlling course (HTCC) are viewed in this paper. The main principles of realizing HTCC are these requirements:

Journal of Engineering Sciences, Volume 4, Issue 2 (2017), pp. H 9–H 11

─ system has to be cross – platform, i.e. common orientation to using created HTCC at any type of computer and in any operating system, which has embedded tools of Java virtual machine (JVM) support; ─ hypertext and multimedia support; ─ it has be easy to create and add new training courses, to replace and delete outdated fragments; ─ orientation for no programmers users, e.g. tutors of humanitarian; ─ media, technical subjects, etc.; ─ executable code of active training components (e.g. subsystem of control and self – control) has to be executed while shipped to the end – user (student); ─ high-level security.

HTCC are the hypertext and multimedia HTML – files (declarative component) with the embedded Java –apples (executable active component), oriented to usage at the various apparatus and program platforms in Internet/Internet networks, and also in the file-server LAN or (if necessary) at a single computer [3–5]. The modern object-oriented Java language, Providing developing of the cross-platform software, and HTML, to create bright and colorful hypertext and multimedia training courses, practical works and controlling environments, altogether as a set of interrelated Web-pages were chooser as the base tools of realizing the suggesting method. Relations between components can be set both in syntax and semantic-logical levels, matches the proper professional knowledge about studied subject.

2.3

Functional Structure of Piece 1.0

Base functional component is an interactive intellectual instrumental environment, designed to create new hypermedia training courses. It contains set of tools and adjustable system of wizards. They help to manage the system during automatic generation of source code mode of training courses. Also they order, regulate and make easy processes of filling out databases and knowledge bases of created HTCC with structured training information of specific data domain. The powerful and adaptable environment of visual programming in Java language Symantec Visual Café Database Development Edition 3.0 was used to realize this component. System-shell PIECE consist of 3 base functional components (Fig.1).

Figure 1 – Schema of functional structure of PIECE

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Computational Engineering

Base component provides solving of the two main functional problems of HTCC synthesis: ─ how to create and edit adaptable tests, including various types of answers; ─ how to create, add and delete structured hypermedia information in training courses. When solving the first problem, trainer can create convenient additional component of automated control and self-control of students’ knowledge, possible online. PIECE supports 4 main types of questions. They are: ─ ─ ─ ─

choosing one right answer from many others; choosing some right answers from many others; string input; number in some range input.

In future number of types of the questions will grow, according to the requirements of corresponding training data domain. The environment has intuitive interface, contains wizards, which direct actions of developer and enables users with insufficient preliminary (the system is designed for users with various preliminary level) easily and quickly develop their own controlling tests. Solution to the second problem of synthesis HTCC enables users to create structured information contents of course as a system of interrelated training Web-pages with embedded Java-applets, and also files, contains test questions and variants of its answers. There are also instructions on designing the courses. After successful solution to the problems of functional synthesis HTCC of specific data domain, PIECE automatically extends its interface, adding new menu item. Also PIECE automatically create new folder and copy all files in it, related to the new training course. Andin conclusion, PIECE sends parameters of the knowledge verify to the controlling program. Second functional component is a set of special ordered files and its service programs. It is called repository (system database). Repository contains information about all new changes designed by PIECE courses or about courses already in use. Data about each course registered in the system are situated in a single folder, inside the main folder PIECE. All the relations between files are set inside this folder, that’s why after creating new HTCC it is enough to move new folder to the appropriate Webserver, local file-server or to the single computers, used for training. Third component is a final product i.e. specific instance of HTCC, created during dialog with trainer via base component of PIECE. Generated HTCC is a filled with a training information set of hypermedia files, includes embedded cross-platform executable code in the form of Java-applets, intended to be executed while shipped to the students computer. HTCC is oriented to the comfortable and ergonomic presentation of the training information and as well as to the organization of effective automated control and self-control of students’ knowledge. After reviewing each fragment of training hypertext and work with active and passive multimedia

information and reference subsystems user can go on to the verification of obtained knowledge. User will pass the set of tests in this mode. And according to the answers he will get integrated mark. Developing environment (base component of PIECE) can be executed from Visual Cafe or from the applet viewer of Sun Java Development of Sun Java Development Kit (JDK) 1.1.x. After interactive synthesis of the second component it has to be moved to the server, where programs of knowledge verification it has to be moved to the server, where programs of knowledge verification and also set of web-pages, which forms the main homepage of PIECE are situated [6–9]. When handling the web-site through Internet, where PIECE is located, user remotely reads training hypertext, supplied (if necessary) with multimedia fragments. Also he can test his knowledge. Program will be executed while shipped to the client’s computer. In Intranet networks this process is the same. In file-server LANs, working under such operating systems, as Novell Netware3.x or 4.x, base component of PIECE has to be located at the file-server. Then it can be opened as an ordinary Web-page with the help of browser with Java supply. It is possible to use PIECE at a single local computer. This time it is necessary to open Web-page located at the user’s hard disk in browser.

2.4 The basic technological phases of working with PIECE 1.0 First technological phase is creating test questions file on selected topics. Menu item File/Create, located at the first dialog window of the wizard, is used to pass this phase. While forming the test question user has to define its type. Next dialog Window has to contain the text of the question and the proper image for it. To view previously created questions select menu item Question/View all to save file of test questions select menu item File/Save. The extension must be *.quest. This wizard is also used to create answers on questions.

Menu item Link the whole training course is used for linking altogether the components of the training course. To add an icon of new course into main menu of PIECE it is necessary to select Course/Add menu item and set a unique identifier of the course. After that a anew folder will appear inside the PIECE folder. The main training file, file of questions, demo examples and generated Web-pages, serving the course will be copied there. To install PIECE into the Web-server it is enough to copy folder containing PIECE. Thus training course can be created locally and published in the Web-server. Student has to open index.html file in the root directory of PIECE folder to read all the courses, included into the PIECE. It is Possible to do so on the Web-site, as well as at the LAN at a single machine.

3 Conclusions The closest perspective for system enhancement is the development of a subsystem. Its Purpose is to manage the processes of automated filling the created courses with training information, that is based on calling the system of interrelated dynamic templates and responding wizards set, adaptively. They are needed for supporting processes of interactive input of training information and for creating the screen forms with embedded hypermedia inserts. At the moment trainer-developer using this subsystem can either choose the proper wizard, or apply adaptive and simple script language to realize tools of the training information reflection. Actual questions are also the realize tools of the training information reflection. Actual questions are also the setting of the security system, running the individual or class electronic log. The questions of developing the visual instrumental system PIECE designed to automate processes of creation the cross- platform hypermedia training and controlling course (HTCC) are viewed in this paper.

References 1. Salaimeh, S. A., Batiha, Kh. (2006). Business Process Simulation with Algebra Event Regular Expression. Information Technology Journal, Vol. 5, No. 3, 583–589. 2. Batiha, Kh., Salaimeh, S. A. (2006). E-Learning. Leonardo Electronic Journal of Practices and Technology, pp. 1–4. 3. Batiha Kh., Salaimeh, S. A., Besoul, Kh. A. (2006). Digital Art and Design. Leonardo Journal of Science, pp 1-8. 4. Salaimeh, S. A., Zaher, A. A. (2011). Developing enterprise system with CORBA and JAVA integrated technologies. Journal annals computer science series, Vol. 9, No. 1. 5. Salaimeh, S. A., Zaher, A. A. (2011). Using Java Technologies in Developing Enterprise Systems. Australian Journal of Basic and Applied Sciences. 6. Salaimeh, S. A., Saraireh, Z. A., Rawashdeh, J. H. A. (2015). Design a Model of Language Identification Tool. International Journal of Information & Computation Technology, Vol. 5, No. 1, 11–18. 7. Michael, J. L. (2017). Object-Oriented Programming Featuring Graphical Applications in Java. 8. Sarcar, V. (2016). Interactive Object Oriented Programming in Java: Learn and Test Your Skills, Apress. 9. Sanders, K. E., Bam, A. V. (2005). Object-oriented programming in Java a graphical approach, Addison Wesley.

Journal of Engineering Sciences, Volume 4, Issue 2 (2017), pp. H 9–H 11

H 11

JOURNAL OF ENGINEERING SCIENCES УРНА ІН

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DOI: 10.21272/jes.2017.4(2).h12

Volume 4, Issue 2 (2017) UDC 519.252; 53.088.3; 629.3.01

Development of the method for estimating the inertia radius relative to the vertical axis of the car Podrigalo M. A.1, Korobko А. I.2*, Dubinin E. A.3, Tarasov Yu. V.3, Baytzur M. V.3 1

Kharkiv P. Vasylenko National Technical University of Agriculture, 44 Alchevskih St., 61002, Kharkiv, Ukraine; L. Pogorilyy Ukrainian Scientific Research Institute of Forecasting and Testing of Machinery and Technologies for Agricultural Production, Kharkiv branch, 236 Velyko-Panasivska St., 61139, Kharkiv, Ukraine; 3 Kharkiv National Automobile and Highway University, 25 Yaroslava Mudrogo St., Kharkiv, Ukraine Article info: Paper received: The final version of the paper received: Paper accepted online:

*Corresponding Author’s Address: November 4, 2017 December 3, 2017 December 4, 2017

ak82andrey@gmail.com

Abstract. The method of estimating the inertia radius relative to the vertical axis of the car is proposed. This allows a third to reduce the relative error of its definition. A refined formula for calculating the radius of inertia design with respect to the vertical axis of the car is proposed. The use of the proposed formula reduces the error of determining the radius of inertia from 21–27 % to 5 %, and the error of determining the inertia moment for the car from 46– 61 % to 10 %. A method for assessing the adequacy of the results of theoretical and experimental studies is proposed. The use of the method has shown that the refined formula for calculating the radius of inertia relative to the vertical axis of the car makes it possible to reduce the probability of mismatching the results up to three times. Keywords: moment of inertia, radius of inertia, error, car, method, methodical error, mismatch of results.

1 Introduction The inertia moment relative to the vertical axis substantially affects the handling and stability of the car. At the design stage of the car methods for determining the inertia moment relative to the vertical axis not accurate enough. The test stand is difficult to determine the inertia moment need to design. Probabilistic methods to calculate the inertia radius relative to the vertical axis of the car propose by different authors. More than 30 % is error for the probabilistic method. The inertia radius has degree two in the formula the inertia moment. In this article, a method for estimating the inertia radius relative to the vertical axis of the car was offered. It is based on the results of experimental studies are known. This reduces the methodological error in three times. The task is to determine the inertia moment relative to the vertical axis for the car in the design phase occurs. The inertia moments and position of centre of mass have a significant effect on stability and handling for the car. The center of mass is characterized by horizontal coordinates and vertical coordinates of the car. The coordinates of the center of mass in the design are determined by graphical and analytical method.

H 12

Computational Engineering

The essence of the method. The essence of the method. Find on the drawing the relative position of the center of mass for each unit or item of the car . To find its distance to a particular axis. Find its distance to a particular axis. The horizontal coordinate b for the center of mass of the car (from rear axle) can be found by the following formula: b

G1x1  G2 x2  G3 x3  Ga

 Gi xi

  qi xi i 1

(1)

where Ga – the weight of the car, N; G1, G2, G3, Gi – the weight individual components of car that, are used in the determination of the position of its center of mass; qi – the relative weight of the i-th unit; qi 

Gi Ga

(2)

x1, x2, x3, xi – the shoulders of the moments of forces of attraction for the elements of the car relative, to the rear axle; n − the number of elements which are taken into account when calculating the center of mass of the last. The location of the other centre of mass for the car is determined similarly.

The question arises. Graphical and analytical method is used to assess the inertia moment relative to the vertical axis of the car. The obvious is that n

 Gi  xi  b   0

(3)

i 1

The inertia moment relative to the vertical axis of the car is found as n G Gi 2  xi  b    i izi2 i 1 g i 1 g n

I cz  

(4)

where izi – the inertia radius relative to the vertical axis of the car the i-th element, m; g – acceleration of gravity, g = 9,81 m/s2. It is impossible to determine Izc using the graphical and analytical method. It is difficult to determine izi. In the paper [1], a probabilistic method is proposed for finding the inertia radius relative to the vertical axis of the car. In the present paper, the formula there exists iz 

1 B2 1 ab   ab 2 12 6

(5)

where a – the projection of the distance from the front axle to the center of mass of the car for the horizontal plane, m; B – automobile track, m. The authors built a probabilistic model in [2]. The displacement of the centers of mass of the car parts from the front axle and the rear axle in the transverse direction was taken into account. The formula was updated

B2 b   1 1  iz      ab   4 a  2 6 

(6)

The results of the experimental determination for the inertia moments and the inertia radius are relative to the vertical axis of the car in [3]. The results are shown for the ten models in Table 1. In Table 2 estimation of the relative error for determining the mathematical expectation of the inertia radius relative to the vertical axis of the car are shown. The inertia radius relative to the vertical axis defined by the formulas (5) and (6) (in comparison with the experimental results [3]). The results are shown in Table 2 were established. The relative error for the determination of the inertia radius relative to the vertical axis iz by the formula (5) is in the range to14.3–36 %, and according to the revised formula (6) is to 6.83–34.25 %. Let us define the expression to calculate the error of the inertia moment relative to the vertical axis Izc. It is necessary to relate the error of determining the inertia radius relative to the vertical axis iz and the inertia moment relative to the vertical axis Izc  I zc  1

I zc ma iz2  ma iz 2 iz 2 1     I zc ma iz2 iz2

 iz  iz 

iz2



iz2 iz2

iz   iz2 iz2

(7) 2 iz .

where ΔIz, Δiz – the absolute error in the determination iz and Izc, respectively.

Table 1 – The results experimental determination of the inertia moments and the inertia radius relative to the vertical axis OZ of the car The parameters ma, kg Izc, kg m2 iz, m a, m b, m L, m h, m B, m

A 2 119 4 571 1.469 1.470 1.530 3.000 0.500 1.470

B 2 590 6 327 1.563 1.680 1.350 3.030 0.500 1.485

C 2 178 5 435 1.579 1.500 1.550 3.050 0.500 1.570

D 883 1 099 1.115 0.900 1.280 2.180 0.400 1.280

The cars E F 2 050 1 010 5 444 1 030 1.629 1.009 1.490 1.240 1.700 1.020 3.200 2.260 0.500 0.450 1.568 1.107

G 795 1 050 1.149 1.322 0.958 2.280 0.473 1.117

H 628 481 0.875 0.863 1.167 2.030 0.421 0.995

I 824 1 020 1.113 1.368 1.012 2.380 0.421 1.166

J 1 167 2 099 1.341 1.148 1.552 2.700 0.510 1.323

Table 2 – Comparison of results for calculation by formulas (5) and (6) The parameters

The cars A 1.469

B 1.563

C 1.579

D 1.115

E 1.629

F 1.009

G 1.149

H 0.875

I 1.113

J 1.341

1.142

1.148

1.170

0.844

1.213

0.857

0.859

0.766

0.897

1.018

iz , m (6)

1.186

1.164

1.217

0.931

1.272

0.871

0.864

0.819

0.904

1.089

  iz  , % (5)

28.63

36.16

35.01

32.09

34.29

17.73

33.82

14.30

24.01

31.17

  iz  , % (6)

23.86

34.25

29.75

19.73

28.10

15.86

33.01

6.83

23.07

23.10

iz, m iz , m (5)

Journal of Engineering Sciences, Volume 4, Issue 2 (2017), pp. H 12–H 15

H 13

The largest error δizc when the lower sign on the right side of expression (7). In this case, when δiz = 0.35 value δIzc = 0.82. In this case, when δiz = 0.35 value δIzc = 0.82. Because it creates more than 80 % of the error to determine the inertia moments relative to the vertical axis δIzc. The range of variation of the random variable iz, adopted in [1, 2], is big. Therefore, a large error for a probabilistic method to determine the inertia radius is relative to the vertical axis of the car. The purpose of the study: improving the accuracy of measurement the inertia radius relative to the vertical axis of the car at the design stage. To achieve this goal it is necessary to solve the following tasks:

─ to offer the calculated dependence, which will allow, at the design stage of the car, to increase the accuracy of determining the inertia radius relative to the vertical axis; ─ to assess the adequacy of calculation results to experimental results.

2 Results 2.1 The calculated dependence for determining the inertia radius relative to the vertical axis of the car Experimental determination of the inertia radius relative to the vertical axis of the car iz is shown in Table 1. Analysis of the results shows the following. The value iz is close to the results of the calculation for the inertia radius relative to the vertical axis according to the formula iz  ab

(8)

The value iz is the mean quadratic value of the coordinate a and coordinate b the center of mass of the car. It should be said. Formula (8) was determined by E. A. Chudakov [4] and the following researchers [1, 5, 6]. It is a condition of ensuring the lateral stability of the rear axle of the car at corner entry and exit. The results of the calculation by the formula (8) given for ten models (those that are shown in Table 1) in Table 3 are shown. The calculated values and the experimental results [3] are compared among themselves. Shows the following for analysis of the results (given in Table 3). Value of the difference absolute theoretical values and experimental values for the inertia radius relative to the vertical axis of the car calculated by the formula (8) does not exceed 15 %. If we ignore the error for car F and car H. Other 8 cars |δiz| does not exceed 6 %. Given the measurement errors of the inertia radius relative to the vertical axis of the car, for cars A, B, C, D, E, G, I, J, the accuracy of determining the moment of inertia Izc 12 % does not exceed. For car F δIzc = 24 % and 32 %. For car H – δIzc = 31.33 %. To sum up. The accuracy of the calculations increases when the mathematical expectation of the inertia radius relative to the vertical axis of the car about a vertical axis H 14

Computational Engineering

is used equation (8). The average relative error decreases from 21–27 % to 5 % compared to the calculations on (5) and (6), which was used earlier. This means that the average error of determination for the inertia moments relative to the vertical axis of the car decreased from 46– 61 % to 10 %. Table 4 shows the calculation results for the ratio in the ten car models that were considered. The average value determined. The average value of the absolute value is the value 0.063, as shows the analysis of the calculation results (Table 4). S. Litvinov in [5] says: the study of stability and control may be greatly simplified; the inertia radius relative to the vertical axis of the car must be determined in the square, through the product ab, that is, by using the relations (8). M. Julien [7] and A. S. Dobrin [8, 9] did the same. In the paper [5] with reference to the results of the study [6], data characterizing the limits of the relationship for passenger cars different classes. The inertia radius relative to the vertical axis of the car expresses the following relationship iz  A ab

(9)

where A – the factor correction that is determined from the ratio A

iz ab

(10)

In Table 5 shows the values of the parameter A obtained for ten models are given in Table 1. The parameter A in 42 implementation (given in [5] and Table 5) for estimation of the average value can be used. Two of the car's load (specified in [5]) as the implementation can be used. As a result, define A  A   A  0,925  0,065

(11)

where σА − the standard deviation of the parameter A. The calculated value of the inertia radius relative to the vertical axis of the car izp within one standard deviation can be determined by the formula A  A   A  0,925  0,065

(12)

The moment of inertia Izcp relative to the vertical axis of the car estimated value A  A   A  0,925  0,065

(13)

To convert the expression (13) I zcp  ma 0,860ab  ma 0,120ab  I zcp  0,120ma ab

(14)

where I zcp − the average value of inertia moment relative to the vertical axis of the car I zcp  0,860ma ab

(15)

Table 3 – Comparison of calculation results by formula (8) and the results of the experiment [3] Parameters iz, m iz . m Δiz. m δiz. % δIzc. %

B 1.563

C 1.579

D 1.115

The cars E F 1.629 1.009

G 1.149

1.500

1.620

1.525

1.073

1.591

1.125

–0.032 2.17 4.39

–0.057 3.6 7.33

0.054 –3.4 6.92

0.042 –3.8 7.74

0.038 –2.3 4.65

–0.116 11.5 24.32

0.024 –2.1 4.24

A 1.469

H 0.875

I 1.113

J 1.341

1.003

1.177

1.334

–0.128 14.6 31.33

–0.064 5.7 11.72

0.007 0.52 1.04

Table 4 – Results to determine value Parameters

The cars A

iz . m

1.500

1.620

1.525

1.073

1.591

1.125

1.003

1.177

1.334

Δiz. m

–0.032

–0.057

0.054

0.042

0.038

–0.116

0.024

–0.128

–0.064

0.007

i z iz

0.021

0.035

0.039

0.024

0.103

0.021

0.128

0.054

0.005

1.594 1.405 1.468

1.722 1.518 1.563

1.621 1.429 1.579

1.140 1.005 1.115

1.691 1.491 1.629

1.196 1.054 1.009 0.063

1.196 1.054 1.149

1.066 0.940 0.875

1.251 1.102 1.113

1.419 1.250 1.341

izmax. m izmin. m iz. m average value

Table 5 – The parameter A Parameters iz. m ab . m А

A 1.469 1.500 0.979

B 1.563 1.620 0.965

C 1.579 1.525 1.035

D 1.115 1.073 1.039

The cars E F 1.629 1.009 1.591 1.125 1.024 0.897

G 1.149 1.125 1.021

The error relative in determining Izcp within the standard deviation of the inertia radius iz  I zcp

m ab 0,12ma ab  a   0,139 I zcp 0,86ma ab

up  

(16)

Data analysis ([5] and Table 5) following. Only 13 implementations outside the interval out of the 42. This is 1 standard deviation of the inertia radius relative to the vertical axis of the car.

2.2 Assessing the adequacy of results for theoretical and experimental studies The results for theoretical and experimental research are random variables. Make assumption. The data is distributed according to the normal law. We use the quantile for normal distribution of the composition of two random variables – inertia radius for experimental and theoretical by certain [10]

H 0.875 1.003 0.872

I 1.113 1.177 0.946

ize  izp

 e2  p2

J 1.341 1.334 1.005

(17)

where ize , izp – the average value of the inertia radius, defined by experimental and calculated, respectively; σе, σр – average quadratic error of definition izе and izр, respectively. Table 6 shows the calculation of the quantile up and the probability of a discrepancy between the results of theoretical studies and experimental studies for 10 model car the inertia radius relative to the vertical axis, are given in Table 1. The calculated value of the standard deviation the inertia radius of the car to the vertical axis

Journal of Engineering Sciences, Volume 4, Issue 2 (2017), pp. H 12–H 15

 p  0,065 ab

(18)

H 15

Table 6 – Assessing the adequacy of the results for determination the inertia radius of the car to the vertical axis, a theoretical way and experimental way The cars

Parameters

ize , m

1.469

1.563

1.579

1.115

1.629

1.009

1.149

0.875

1.113

1.341

izp , m

1.387

1.498

1.411

0.992

1.472

1.041

0.928

1.089

1.234

up р

–0.421 0.660

–0.309 0.620

–0.847 0.800

–0.882 0.810

–0.759 0.760

–0.219 0.580

–0.738 0.770

–0.406 0.655

–0.157 0.560

–0.617 0.730

3 Conclusions The proposed revised the formula to calculate the inertia radius of the car to the vertical axis at the design stage. which is the result of the study. Using the proposed formula allows to reduce the error in determining the inertia radius from 21–27 % to 5 %.

The accuracy of determining the inertia moment of the car is reduced from 46–61 % to 10 %. Method for assessing the adequacy of results of theoretical studies and experimental studies. offered by us. showed the following. Using the refined formula for calculating iz reduces the likelihood of a mismatch results three times.

References 1. Podrigalo. M. A.. Volkov. V. P.. Kyrchatyi. V. Y.. & Boboshko. A. A. (2003). Manevrennost’ i tormoznye svojstva kolyosnykh mashyn [Maneuverability and Brake Properties of Wheeled Cars]. KhNADU. Kharkiv [in Ukrainian]. 2. Podrigalo. M. A.. Dubinin. E. A.. & Glushhenko. V. V. (2015). Utochneniye veroyatnostnogo metoda opredeleniya radiusov inercii kolesnoj mashyny [Clarification of the probabilistic method for determining the radii of inertia of a wheeled car]. Automobile transport. Collection of scientific works. No. 37. 116–122 [in Russian]. 3. Ellis. D. R. (1975). Upravlyaemost’ avtomobilya [Driving ability of the car]. Moscow. Mashynostroyeniye [in Russian]. 4. Chudakov. E. A. Ustojchivost’ avtomobilya pri zanose [Stability of a car with a skidding]. AN SSSR [in Russian]. 5. Litvinov. A. S. (1971). Upravlyaemost’ i ustojchivost’ avtomobilya [Controlability and stability of the automobile]. Moscow. Mashynostroyeniye [in Russian]. 6. Mitschke. M. (1960). Fahrtrichtung und Fahrstabilitat Vor vierradrigen Kraftfahrzeugen. Deutsche Kraftfahrtforshung. pp. 135 [in Deutschland]. 7. Julien. M. A. (1955). Etude analytique de la stabilite de routedes voitures automobiles. SJA. No. 4 [in Italian]. 8. Dobrin. A. S. (1966). Issledovaniye dvizheniya avtomobilya po zadannoj traektorii [Investigation of the motion of a car in a given trajectory]. Proceedings of the workshop on controllability and stability of the car. No. 1. [in Russian]. 9. Dobrin. A. S. (1968). Ustojchivost’ i upravlyaemost’ avtomobilya pri neustanovivshemsya dvizhenii [Stability and controllability of a car with non-steady motion]. Automobile industry. No. 9. 23–27 [in Russian]. 10. Podrigalo. M.. Isakova. O.. & Korobko. A. (2017). Novyy sposib otsinyuvannya zbihu rezul'tativ teoretychnykh i eksperymental'nykh doslidzhen' [A new scientific approach to evaluating the results of research on theoretical and experimental]. Metrology and instruments. Scientific and production journal. Vol. 5 (67). 48–51 [in Ukrainian].

H 16

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