3.1. Analytical and numerical modeling
-
a)
Finite element mathematical modeling
The developed mathematical model applies to dynamic systems with a finite number of degrees of freedom through the analytical formulation of structure dynamics with added damping. The analytical model of this formulation (the matrix differential equation of vibrational motion) is the one from classical dynamic analysis. In this context, loads or loading conditions vary over time and are applied instantaneously. Dynamic loads involve oscillating weights, impacts, collisions, and unpredictable amounts, and therefore, this case it supposes involve [
20]:
- ➢
transient dynamic evaluation, employed to calculate the feedback of a structure to external loads that fluctuate unpredictably over the period.
In dynamic analysis, the matrix equations for force equilibrium are applied to a dynamic system [
20], [
21]:
- for a structure without foreign load:
- for a system with an external load:
where: M - mass;
- acceleration; C - Rayleigh damping;
- velocity; K - stiffness; X – displacement and F – load (all variabels are in matrical form),
t - time.
By solving the equations (1) and (2), we can obtain the natural frequencies of a structure. The types of loads used in a static analysis are the same as those of a dynamic. The expected results from the software include natural frequencies, displacements, deformations, and stresses. All these outcomes can also be acquired in the total deformation, where
δt is a scalar quantity, and:
where
δx,y,z - the components of deformation along coordinate axes can be obtained in either global or local coordinates.
The associated differential equation has the form [
15]:
in which the matrices and vectors are specific to the dynamic model with added mass (M
+) connected to the primary system through elastic connections (stiffness coefficient K
+), damping connections (damping coefficient C
+) and F
+ - appropriate load.
Here is presented an approach to mathematical modeling established on the utilization of computational instruments for numerical simulations [
22]. The process involves transitioning from problem formulation and equation establishment to the implementation of computational algorithms and analysis of results.
Due to the factors depicted beyond an evaluation of the pumping time should fundamentally differ for evacuating a vessel in the rough vacuum region compared to evacuating in the regions of medium and high vacuum.
In the case of gas evacuation of a vessel in gross vacuum mode (excluding supplementary quantities of gas or vapor), the effective pumping speed, sef of the pump-vacuum chamber assembly, depends only on the required pressure, p (after time t), on the volume, V of the chamber and the pumping time, t.
Accompanied by an invariable pumping speed,
sef and supposing that the maximum pressure reached, p
f (the final/desired pressure) by the chosen pump model, is such that p
f << p, the pressure drop over time, p(t) in a vessel of vacuum is provided by the differential equation of the first order [
2]:
which by integration, considering that the pressure varies from the initial pressure,
p0 = 1,003 mbar at the time
t = 0 to a minimum value,
p (after the time,
t), then the effective pumping speed,
sef could be estimated as a function of the pumping time,
t from equation/relation (5) as follows:
where from result:
Noting
- the dimensionless pressure factor and substituting in equation/relation (7) we obtain that the association amongst the effective speed,
sef and the pumping duration,
t, becomes:
The ratio (
V/sef) =
τ, is commonly defined as a time invariant. Consequently, the pumping duration,
t of a vacuum vessel from atmospheric load to a value of pressure
p, will be:
|
(9) |
The dependency of the
σ parameter on the wished-for pressure is presented in
Figure 5. It must be mentioned that the pumping speed of ordinary pumps drops less than 10 mbar with gas ballast and less than 1 mbar without gas heft. This elementary attitude varies for pumps of different capacities, but it is recommended to not be overlooked in determining the pumping time relying on the pump size. It is emphasized that equations (6 to 9) and also
Figure 5 apply only when the final pressure reached alongside the pump applied is several orders of amplitude lower than the wanted pressure.
In the gross vacuum regime, the capacity of the chamber is determined for the duration engaged in the pumping routine. In the high and ultrahigh vacuum areas, the release of gases from the walls (of the corn seeds and the vessel) exhibits a significant function, in the medium vacuum region, the evacuating process is affected by both quantities. Additionally, in the medium vacuum zone, especially in the situation of rotary pumps, the maximum pressure that can be reached is no insignificant.
If the amount of gas accessing the chamber is established to be Q (in mbar·l/s) from the gas release from the seed enclosures, the chamber, and the leaks, the differential equation (5) for the pumping operation changes into [
2]:
and through the integration of this equation (11), we obtain:
Unlike equation/relation (7), equation/relation (11) does not allow for a definition of the solution for the effective pumping velocity,
sef; therefore, the
sef for a well-known gas release cannot be obtained derived from the pressure drop curve over time without additional knowledge,
Figure 6.
Therefore, in usage, the strategy will necessitate a pump with enough upward pumping speed, calculated from equation/relation (7) as an outcome of the volume of the gas-free chamber and the wanted pumping duration. Instead, the ratio Q/s
ef between the gas release velocity and this pumping speed is established. This ratio must be lesser than the needed pressure; for protection, it should be approximately ten times smaller. If the corresponding situation is not met, a pump with a comparable elevated pumping speed must be selected. In a situation where the pumping process is dominated by residual gas, pumping in a high vacuum region can be described by the relation [
2]:
where:
Vt - is the total volume of the system.
However, by far, the most significant uncertainty associated with pump performance, pressure, flow, and external leaks is due to gas release. Gas release rates can differ by several orders of amplitude, according to the component of a surface, its external intervention, humidity, temperature, and the exposure duration to vacuum. As it usually approaches asymptotically to the final pressure of a system, even small changes in gas loads result in significant differences in evacuation times (see
Figure 6). Vacuum analysis, which aided in selecting a roughing pump, relied solely on the relationship between pressure and the time to reach this pressure, assuming the following relevant hypotheses for such an analysis: the system has no leaks, the pump is 100% productive, and nothing will vaporize in the vacuum vessels.
The calculation application was developed using Microsoft Excel, but any equivalent software to Microsoft Office that includes a spreadsheet with similar features to Excel can be used, making the adaptation of the application relatively easy. The choice of an Excel spreadsheet to simulate the variation of the vacuum system pressure over time is due to its capability to perform numerical description (in a table) applying symbolic statement as thoroughly as visual description using tables constructed for this purpose. The skill to activate and explore numerical, symbolic, and visual description dynamically makes the spreadsheet an essential instrument for promoting conceptualization and algebraic reflection [
22]. Excel uses the VBA (Visual Basic for Applications) language, which is now widely used. It should be emphasized that VBA is a complex programming language. With its help, data can be manipulated, complex tasks automated, interactions with other Office applications can be performed, and much more [
23], [
24].
Using a spreadsheet, we can generate the graph of the precedent response (12) that reveals the relationship between the initial time,
t, and the gas load pressure in the vacuum chamber,
p(
t),
Figure 7. At the aforementioned, it is also feasible to see the so-called state curves, which represent the parametric error of estimation based on experimental data at each moment of the system's operation.
Since the particular solution (12) is a function that depends on parameters,
sef (pumping speed in steady-state),
V (volume of the vacuum chamber), and implicitly by
σ (the dimensionless pressure factor), as well as the initial pressure of the gas load,
p0, at the initial moment
t0 = 0, we will observe how graphic elements are constructed that can be interactively modified using sliders for the constructive parameters of the chamber, diameter (
D), and height (
H),
Figure 7. The design of the spreadsheet itself is indispensable to the development of the calculation section.
It should be emphasized that VBA is a complex programming language. With its help, data can be manipulated, complex tasks automated, interactions with other Office applications performed, and much more [
24], [
25]. Consequently, the relevant VBA editor was used and adapted accordingly for processing and analyzing the results obtained from the simulation. The interface of the "Vacuum Chamber Pressure Variation Simulation.xls" program, on the "Pressure" page, is presented in
Figure 8.
To identify the real or correct values, the absolute error (EA) was calculated. The real values were considered to be the mean values of the data resulting from multiple measurements in physical experiments with corn seeds. The measured average real value for the gas load pressure in the vacuum chamber was 44.273 mbar. The graph of the data obtained from measurements for the pressure variation over time is presented in
Figure 9a. The estimated values of pressure over time for three different values of σ (dimensionless pressure factor), σ = 23.73; 27.05; 32.18, were calculated using the mathematical model adopted in the simulation program, and the data can be observed in
Figure 9b. The average values of the estimated pressures for each of the three data sets were 51.031, 45.920, and 40.140 mbar, respectively, with the estimated average value for all three data sets being 45.698 mbar. For each measurement, the following formula is applied to obtain EA:
The variation of EA for the three sets of estimated pressure data with the created simulation program is presented in
Figure 9c. The trend of the error variation is similar for the three curves shown, with a peak at the moment
t = 0.33 s. The highest peak value of 132.472 mbar was recorded in the dataset with
σ = 23.73, while the lowest peak value of 21.269 mbar is encountered in the curve with σ = 32.18, and for
σ = 27.05, the peak has a value of 85.035 mbar.
It is observed for all three curves that after approximately 2 minutes, the error value significantly decreases, reaching a steady-state value of about 5.161 mbar.
Then, if there are multiple measurements, errors can be summed to obtain the total EA or the average of absolute errors can be calculated by dividing the sum of absolute errors by the number of measurements. The calculation of the average EA for the estimated pressure with the simulation model was performed using the relation:
Therefore, a very small value justifies the correlation between the results obtained through simulation and the real ones.
3.2. Experimental Procedure
For the structural dynamic analysis of the vacuum system under certain loads, the Finite Element Method (FEM) was used, considering the capabilities of the vessel made of stainless steel 316 and the lid made of acrylic plastic. The dynamic analysis process is carried out in the subsequent stage:
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The first stage is the selection of the material and some details. Several materials can be checked under vacuum pressure; however the most regular category spent are metals, plastics, and their composites [
18]. The ANSYS material library provided characteristic values for the materials of the chamber and the lid, as mentioned above, while the temperature and other experimental conditions are detailed below.
- ➢
The second step involves creating the 3D geometry of both the chamber vessel and the lid in the SolidWorks 2022 program (
Figure 10) according to the dimensions (see
Table 1) of the experimental physical model (see
Figure 5).
Modeling the contact-type connections between the vessel and the lid was automatically achieved through the Augmented Lagrange method for solving the nonlinear model of frictionless contacts (
Figure 11a). The discretization was done automatically with default parameters for both the vacuum chamber and the chamber lid. Using the adaptive meshing method, a total of 10,546 nodes and 4,572 elements resulted (8,968 nodes and 4,363 elements for the vessel: 1,578 nodes and 209 elements for the lid). Modeling the constraints was done by fixing the lower edge of the cylindrical vessel. Modeling the loading with variable vacuum pressure over time, applied normally to the surface, according to the relationship, was also performed:
This was achieved by selecting the interior surfaces of the vessel and the lid (see
Figure 5b). The setting of the unit system was done by choosing the metric system (mm, kg, N, s, mV, mA, radians, rad/s, degrees Celsius).
The solution of the physical nonlinear model (without friction) in an average time of 2.45 minutes was performed on an Acer Swift 3 laptop with an Intel CORE I7 6500U processor at a frequency of 2.5GHz, using 0.31GB of the available 8GB RAM. The information is available in the resolution statistical report,
Figure 12. The convergence graphs of force displacement for the solution of the nonlinear problem are visualized in
Figure 13.
The image presented in
Figure 14 illustrates the maximum deformation occurring at the bottom of the chamber as well as the deformation of the lid due to pressure. The maximum deformation of 0.009 mm was observed in the middle part of the lid and decreased radially towards the exterior. On the bottom of the vessel, we find deformations almost halved in order of magnitude, of about 0.004-0.005 mm, with the same decreasing radial distribution.
In addition,
Table 2 summarizes the sample deformation values obtained by structural dynamic analysis depending on the pressure in the vacuum chamber of the test experiment.
As the pressure stresses the walls of the vacuum chamber, Von Mises internal stresses occur in them due to the loading (compressive forces). According to Hooke's law, within the elastic limit, stress is directly proportional to deformation, and here the induced effort in the material of the walls and lid is the reaction to the applied compressive force [
20]. The observed values of Von Mises stresses are presented both in tabular and graphical form.
Figure 15a shows the stress distribution in the walls of the vacuum chamber and lid, with a maximum value in the central area of the vessel bottom due to stress concentration.
Figure 15b depicts the variation of equivalent stresses over time, considering elastic loading, and the results are presented in
Table 3, obtained using structural dynamic analysis.
Following the analysis of the obtained results, as a result of their modeling and post-processing, the following highlights emerge:
In the deformation process of the subassembly elements due to the action of vacuum pressure (
Figure 5b), increased displacements are observed (max. 0.001569 mm) in the central area of the vessel bottom and (max. 0.000869 mm) in the central area of the lid.
The equivalent Von Mises stress has increased values (max 63.92 MPa) in the body of the vessel in the middle area of the lower part, while on the lid, the values are insignificant.
From the analysis of the maximum stress, the main compression load on the chamber body is highlighted, with a maximum value of 74.242 MPa in the connection area from the outside, and the tensile stress is reduced in the contact area with the body of the lid.
The radial normal stresses, especially compression, have reduced values (52.643 MPa) in the joining area of the vertical wall of the vessel with the lower end portion;
Increased values (21.434 MPa) of tangential (circumferential) stresses are highlighted in the body of the chamber in the area with the maximum diameter of its bottom, along with a significantly reduced tensile stress in the body of the lid;
The total maximum value of the system energy over time was 617.65 mJ, with a predominance of 617 mJ in deformation energy and only 2.0225e-006 mJ in kinetic energy. A small deviation was acquired, demonstrating the validity of the conducted virtual experiment.
The significantly reduced values of the structural error field (max 2.4669 mJ) obtained for the chamber body indicate that the stress values are appropriate and close to the real ones. Additionally,
Figure 15 highlights the rapid convergence (79 steps - see also
Table 3) of the solution algorithm, and the computation time is reduced (an average of approximately 16.7 minutes cumulatively).