APPROVAL
‘I hereby approve have read this thesis submitted to the senate of UTeM and have accepted this thesis as partial fulfillment of the requirement for the degree in
Bachelor of Mechanical Engineering (Design and Innovation) ’.
Signature : ……….
Supervisor 1 : EN. MOHD HAIZAL BIN MOHD HUSIN
STUDY OF EXTERNAL NOZZLE DESIGN
SYAUQI BIN MOHD HASHIM
This report is submitted in partial fulfillment of the requirement for the Bachelor of Mechanical Engineering (Design and Innovation)
Faculty of Mechanical Engineering Universiti Teknikal Malaysia Melaka
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DECLARATION
“I hereby, declared this thesis entitled STUDY OF EXTERNAL NOZZLE DESIGN
is the results of my own research except as cited in the references”.
Signature : ... Author’s Name : SYAUQI BIN MOHD HASHIM
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DEDICATION
iv
ACKNOWLEDGEMENT
First of all, I want to express my grateful to Allah S.W.T. for ease the way for me to finish this thesis with achievement and enjoyment. I thankful to Allah for the strength that keeps me standing and for the hope that keeps me believing the positive possibilities for my thesis. Also, I want to express my sincere gratitude to Mr. Mohd Haizal b. Mohd Husin, my supervisor, who have given his whelming support, guidance and consideration in helping me to finish this thesis.
Then, I would like to thank to my family who inspired, encouraged and fully supported me for every trails that comes. In giving me not just financial, but morally and spiritually. To my friends who willingly helped me to gather the necessary data’s and information needed for this thesis.
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ABSTRAK
vi
ABSTRACT
vii
TABLE OF CONTENT
CHAPTER SUBJECT PAGES
DECLARATION ii
DEDICATION iii
ACKNOWLEDGEMENT iv
ABSTRAK v
ABSTRACT vi
TABLE OF CONTENT vii
LIST OF TABLES xii
LIST OF FIGURES xv
LIST OF SYMBOLS xviii
LIST OF APPENDICES xix
CHAPTER I INTRODUCTION 1
1.1 Background Study 1
1.2 Problem Statement 2
1.3 Objective 3
1.4 Scope 4
viii
CHAPTER SUBJECT PAGES
CHAPTER II LITERATURE REVIEW 5
2.1 Introduction 5
2.2 Spray Characteristics 5
2.3 Spray Pattern 6
2.3.1 Hollow Cone 7
2.3.2 Solid Cone 8
2.3.3 Flat Spray 9
2.4 Capacity 10
2.5 Spray Angle 12
2.5.1 Spray Angle Terms 13
2.6 Drop Size 15
2.6.1 Factors that Affect the Drop Size 16 2.6.2 Practical Considerations for Drop
Size Data Use 17
2.7 SolidWorks 2007 Overview 18 2.7.1 Featured SolidWorks Capabilities 20
2.8 COSMOSFloWorks Overview 20
2.8.1 Computational Domain 22 2.8.2 Initial and Boundary Conditions 23
2.8.3 Meshing 23
2.8.4 Solving 24
2.8.5 Getting Results 24
2.9 Rapid Prototyping 25
2.9.1 Basic Work Flow of FDM Machine 26
CHAPTER III METHODOLOGY 27
3.1 Introduction 27
3.2 Chosen Material 29
ix
CHAPTER SUBJECT PAGES
3.3.1 Concept A 31
3.3.2 Concept B 32
3.3.3 Concept C 33
3.4 Nozzle Simulation and Analysis by Using 34 COSMOSFloWorks
3.5 Nozzle Fabrication by Using FDM Machine 41
3.5.1 The Basic Process 43
3.6 Equipments for Experiment 45
CHAPTER IV RESULT & DISCUSSION 48
4.1 Introduction 48
4.2 COSMOSFloWorks 49
4.3 System and General Information 50
4.4 Input Data 51
4.4.1 Initial Mesh Settings 51 4.4.2 Geometry resolution 51 4.4.3 Computational Domain 52
4.4.4 Physical Features 52
4.4.5 Boundary Conditions 53
4.4.6 Goals 56
4.5 The Spray Pattern Results 57 4.5.1 Flow Pattern Result for Concept A 57 4.5.2 Flow Pattern Result for Concept B 61 4.5.3 Flow Pattern Result for Concept C 66
4.5.4 Discussions 70
4.6 Data Analysis 71
x
CHAPTER SUBJECT PAGES
4.7.1 Full Result of Concept A 75 4.7.2 Full Result of Concept B 77 4.7.3 Full Result of Concept C 79
4.8 Experimental Result 82
4.8.1 Experiment to determine the Average Flow Rate & Velocity in House Piping
System 82
4.8.2 Experiment to Determine the Volume Flow Rates and Velocity for Each
Nozzle Concept 85
4.9 Experimental Result for Spray Pattern 89 4.9.1 The Arrangement of the Spray Nozzle
in Applying the Experiment 90 4.9.2 The Spray Pattern Produced (Top
View Angle) 91
4.9.3 The Spray Pattern Produced (Side
View Angle) 92
4.9.4 Discussion 93
4.10 Comparison 94
4.10.1 Comparison of the Spray/Flow Pattern Result (Based on Top View
Angle) 94
4.10.2 Comparison of the Spray/Flow Pattern Result (Based on Side View
Angle) 96
CHAPTER V CONCLUSION & RECOMMENDATION 98
5.1 Conclusion 98
xi
REFERENCES 101
BIBLIOGRAPHY 104
xii
LIST OF TABLES
NO. TITLE PAGES
2.1 Conversion factor applies to specific gravity of the liquid spray 11 (Source: http://www.allspray.com/en/sprayguide.pdf)
2.2 Relationship between capacity and pressure 11 (Source: http://www.allspray.com/en/sprayguide.pdf)
2.3 Theoretical coverage at various distances varies with spray angle 14 (Source: http://www.allspray.com/en/sprayguide.pdf)
2.4 Data illustrates the wide range of possible drop sizes produced 17 by different spray types
(Source: http://www.allspray.com/en/sprayguide.pdf)
3.1 COSMOSFloWorks simulation step-by-steps method for Spiral 35 Nozzle Concept C
(Source: Author)
4.1 System Information 50
(Source: Author)
4.2 General Information 50
(Source: Author)
4.3 Size of the Computational Domain 52
(Source: Author)
xiii
NO. TITLE PAGES
4.5 First boundary condition 54
(Source: Author)
4.6 Second boundary condition 55
(Source: Author)
4.7 The surface goal setting 56
(Source: Author)
4.8 Flow Pattern Result for Concept A 57
(Source: Author)
4.9 Flow Pattern Result for Concept B 61
(Source: Author)
4.10 Flow Pattern Result for Concept C 66
(Source: Author)
4.11 Goals (Concept A) 76
(Source: Author)
4.12 Minimum and Maximum Table 76
(Source: Author)
4.13 Goals (Concept B) 78
(Source: Author)
4.14 Minimum and Maximum Table 79
(Source: Author)
4.15 Goals (Concept C) 81
(Source: Author)
4.16 Minimum and Maximum Table 81
(Source: Author)
4.17 The Volume Flow Rate and Velocity of Water in House 84 Piping System
(Source: Author)
4.18 The Volume Flow Rate and Velocity of Water for Each 87 Nozzle Concept
(Source: Author)
xiv
NO. TITLE PAGES
4.20 The spray pattern result from the top view 91 (Source: Author)
4.21 The spray pattern result from the side view 92 (Source: Author)
4.22 Comparison of the spray pattern between the experimental and 94 theoretical for each concept
(Source: Author)
4.23 Comparison of the spray pattern between the experimental and 96 theoretical for each concept
xv
LIST OF FIGURES
NO. TITLE PAGES
2.1 Hollow cone 7
(Source: http://www.spray.com/services/edu_ref _nozzle_basics.asp)
2.2 Solid cone 8
(Source: http://www.spray.com/services/edu_ref _nozzle_basics.asp)
2.3 (a) Standard Solid cone 9
(b) Spiral Solid Cone 9
(c) Multiple Solid Cone 9
(Source: http://pdf.directindustry.com/pdf/pnr/general - purpose-industrial-nozzles/Show/5289-7879-_5.html)
2.4 Flat spray 10
(Source: http://www.spray.com/services/edu_ref _nozzle_basics.asp)
2.5 Spray angle diagram 12
(Source: http://www.allspray.com/en/sprayguide.pdf)
2.6 Spray coverage 12
(Source: http://www.bete.com/pdfs/ BETE_EngineeringInformation.pdf)
xvi
NO. TITLE PAGES
2.8 RP process in the making 26
(Source: Author)
2.9 Equipment for removing the support material 26 (Source: Author)
3.1 Methodology flow chart 28 (Source: Author)
3.2 Concept A Isometric view 31
(Source: Author)
3.3 Concept A Front View 31
(Source: Author)
3.4 Concept A Top View 31
(Source: Author)
3.5 Concept B Isometric View 32
(Source: Author)
3.6 Concept B Front View 32
(Source: Author)
3.7 Concept B Top View 32
(Source: Author)
3.8 Concept C Isometric View 33
(Source: Author)
3.9 Concept C Front View 33
(Source: Author)
3.10 Concept C Top View 33
(Source: Author)
xvii
NO. TITLE PAGES
3.12 The Stratasys FDM 400 mc machine specifications 42 (Source: http://pdf.directindustry.com/pdf/stratasys/fdm
-400mc/21791-23583-_2.html)
3.13 Three different nozzles that been produced by Rapid Prototyping 45 (Source: Author)
3.14 Equipment for experiment 46
(Source: Author)
4.1 Velocity scale 49
(Source: Author)
4.2 The COSMOSFloWorks Analysis Tree that shows the defined 54 boundary conditions and engineering goal.
(Source:Author)
4.3 Position to take time reading of 1 liter of water 82 (Source: Author)
4.4 The water tap lever position (before and after) 83 (Source: Author)
4.5 The actual spray nozzle; (a) Concept A, (b) Concept B, 85 (c) Concept C
(Source: Author)
4.6 The exact arrangement of equipment for the experiment 86 (Source: Author)
4.7 The connection of nozzle with the hose-pipe 86 (Source: Author)
xviii
LIST OF SYMBOLS
CAE = Computer-aided engineering CFD = Computational fluid dynamics FSI = Fluid structure interaction CNC = Computer numerical control CAD = Computational-aided design 3-D = Three dimensions
2-D = Two dimensions gpm = Gallons per minute lpm = Liter per minute lbs/gallon = Pounds per gallons
C1 = Capacity
P1 = Pressure
VMD or D v0.5 = Volume Median Diameter MMD = Mass Median Diameter SMD or D32 = Sauter Mean Diameter NMD.or.D No.5 = Number Median Diameter μm = Micro meter
RSF = Relative Span Factor Dmax = Maximum drop size Dmin = Minimum drop size
xix
LIST OF APPENDICES
NO. TITLE PAGES
A Drawing of Spray Nozzle Concept A 105
B Drawing of Spray Nozzle Concept B 108
C Drawing of Spray Nozzle Concept C 111
D Others Result from COSMOSFloWorks Simulation 114
E Gantt Chart 117
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CHAPTER I
INTRODUCTION
1.1 BACKGROUND STUDY
A nozzle is a mechanical device or orifice designed to control the characteristics of a fluid flow as it exits an enclosed chamber or pipe.
A nozzle is often a pipe or tube of varying cross sectional area and it can be used to direct or modify the flow of a fluid (liquid or gas). Nozzles are frequently used to control the rate of flow, speed, direction, mass, shape, and the pressure of the stream that emerges from them.
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The spray pattern of the nozzle gives us different patterns such as Solid Cone, Hollow Cone and Flat Spray. The spray pattern that we want to study for this project is the solid cone spray pattern.
Solid cone nozzles will form complete spray coverage in a round, oval or square shaped area. Usually the liquid is swirled within the nozzle and mixed with non-spinning liquid that bypasses an internal vane. Liquid then exits through an orifice forming a conical pattern. Spray angle and liquid distribution within the cone pattern depend on the vane design and location relative to the exit orifice. The exit orifice design and the relative geometric proportions also affect the spray angle and distribution.
Based on the solid cone spray nozzle that are already in market, an analysis will be made based on this nozzle from its spray pattern and fluid flow simulation. With the use of computer-aided design (CAD) software and computational fluid dynamics (CFD), a research will be conducted to make sure that the nozzle model that we design achieved high specification in its categories.
1.2 PROBLEM STATEMENT
Based on the past research and study on the solid cone spray nozzle, show that many applications can be performed by this spray nozzle in a daily life and industry. There are many things to be considered in order to get the best solid cone spray. Some of the problems that occur due to improper design of solid cone spray nozzle such as non-uniform coverage of the spray in period of time, the lifecycle of the nozzle are not durable compared with the time usage. This will cost more for the consumer for the maintenance.
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abrasive, and the materials we mix into it are even more abrasive. To such an extent, that a brass nozzle's orifice will begin to wear after only 10 hours of use at 100 pounds pressure.
Nozzle wear means that the orifice of the tip, so carefully engineered to produce an optimum spray pattern becomes deformed, which distorts the spray pattern, producing droplets that are larger than intended, uneven band application and, of course, higher volumes of material per acre.
Many things to be considered in order to get the best solid cone spray of the spray nozzle especially spiral nozzle. Many users don’t have enough information and guidance when it comes to choose the right spiral nozzle. They were uncertain about the wide application of spiral nozzle in industry especially in washing process. The spiral nozzle can also been considered for dish wash application because of its good properties in spray distribution.
Hope that this study will help to discover, design, and analyze the common problem of spray nozzle application and able to propose the better nozzle especially the spiral nozzle type. This study will focus more on the external design of the nozzle rather than the internal. In the end, the main usage of the nozzle that been studied will be useful for the dish wash spray application.
1.3 OBJECTIVE
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1.4 SCOPE
The scope of this project will cover:-
1. Designing - Study the external design of the solid cone spray pattern nozzle. Generate design concept for nozzle which will give the best solid cone spray pattern. Applied the design through Computer-Aided-Design software (Solidwork 2007 are recommended).
2. Analyzing – Develop a Computational Fluid Dynamics (CFD) model. By using the COSMOS FloWorks software, simulate the fluid flow through the nozzle to get the solid cone spray pattern. Analyze the collected data to verify the best solid-cone spray pattern that we can get.
3. Fabrication – Fabricate the concept design of the nozzles by using Rapid Prototyping.
4. Testing – Test with the actual spray nozzle that been produced by rapid prototyping process so that it can be applied for dish wash spray application.
1.5 CONTENT OVERVIEW
