Srečko Glodež

The plate heat exchanger (PHE) is a component that provides heat to be transferred from hot water to domestic cold water without mixing them with high efficiency. Over the lifetime of the PHE, cyclic pressures act on the brazing points and the plates, and this may lead to fatigue failure. The fatigue behaviour of the PHE, designed using copper-brazed 316L stainless steel, was investigated in this study. First, the fatigue tests under the load ratio R = 0.1 were performed on the Vibrophore 100 testing machine to obtain the S-N curve of the analysed brazed joint. Based on the obtained experimental results, an appropriate material model of the analysed brazed joint has been created, which was validated with numerical calculation in the framework of a program code Ansys. A validated material model was then used for the subsequent numerical analysis of PHE. In order to carry out a numerical calculation using the finite element method (FEM), a three-dimensional model of the heat exchanger was created based on the previous scanning of PHE-geometry. Thereafter, the geometry was parameterised, which allowed us to perform parametric simulations (monitoring different responses depending on the input geometry). Numerical simulations were carried out in the framework of the Ansys 2023-R1 software, whereby the obtained results were analysed, and the responses were appropriately characterised according to previously determined load cases.

A computational model for analysing the tooth deflection of polymer gears is presented in this paper. Because polymer gears have less stiffness compared to metal gears, the proposed approach considers a comprehensive analysis to determine the most suitable numerical model, i.e., the number of teeth that should be modelled for a given gear’s geometry and material. The developed computational model has been evaluated using a spur gear pair, where the pinion made of POM was meshed with a support gear made of steel. Material properties were assigned with linear elastic characteristics for the gear, while the pinion was characterised by hyperelastic properties using POM material. Furthermore, a nonlubricated frictional contact between the gear and pinion was considered in the numerical computations. The computational results that were obtained were compared to the empirical results according to VDI 2736 guidelines. Here, the computational approach showed more accurate results due to the hyperelastic material characteristics of POM and the simulation of multiple teeth meshing. However, VDI 2736 calculation showed comparability with the computational results, with a slightly larger deviation at higher loads. In this respect, the proposed computational approach is more suitable for analysing the tooth deflection of polymer gears under higher loads.

This study presents a comprehensive analysis of different coating materials on the POM substrate. Specifically, it investigated physical vapour deposition (PVD) coatings of aluminium (Al), chromium (Cr), and chromium nitride (CrN) of three various thicknesses. The deposition of Al was accomplished through a three-step process, particularly plasma activation, metallisation of Al by magnetron sputtering, and plasma polymerisation. The deposition of Cr was attained using the magnetron sputtering technique in a single step. For the deposition of CrN, a two-step process was employed. The first step involved the metallisation of Cr using magnetron sputtering, while the second step involved the vapour deposition of CrN, obtained through the reactive metallisation of Cr and nitrogen using magnetron sputtering. The focus of the research was to conduct comprehensive indentation tests to obtain the surface hardness of the analysed multilayer coatings, SEM analyses to examine surface morphology, and thorough adhesion analyses between the POM substrate and the appropriate PVD coating.