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Super Critical Carbon Dioxide Metal Working Fluid Delivery System Steve E Super Critical Carbon Dioxide Metal Working Fluid Delivery System Steve E. Hecker, Daniel R. Leader, Daniel S. Merz, and David P. Powers ME450, Team 26 Winter 2008 Section Instructor: Steve Skerlos Department of Mechanical Engineering University of Michigan Ann Arbor, MI 48109-2125 SECTION 6 April 15, 2008 EXECUTIVE SUMMARY Metal working fluids (MWFs) are used to provide cooling and lubrication for metal machining processes. Industry uses aqueous metal working fluids composed of oil, water, surfactants, and additives. This form of cutting fluid is extremely expensive, harmful to the environment, and hazardous to workers. A system using super critical CO2 (scCO2) and soybean oil was developed and works better than conventional MWFs for many machining processes. Our task was to enhance the current scCO2 system by increasing the flow rate of the cutting fluid, designing a subsystem to deliver continuous oil flow to the pressure vessel, designing an oil refill sensor to alert the user when the pressure vessel is low, and designing a method to vary the concentration of oil being delivered to the workpiece. We conducted research to determine products that would fulfill our design specifications. We purchased the P-350 pump from Thar Technologies increasing the flow rate by a factor of 7. We recommend using a HPLC pump to deliver continuous oil flow into the pressure vessel. However, this was not incorporated into our final design. Two thermocouples were used to detect the difference in temperature gradients for the oil and scCO2. The differences in heat capacities for the oil and scCO2 will allow the used to detect when the oil level is low. Lastly, we added multiple inlets for CO2 that increased agitation of the scCO2 and oil mixture thereby increasing the concentration of oil dissolved in scCO2. A fabrication plan was created for a pressure vessel mount and clamp. A stainless steel mount was machined to support the weight of the pressure vessel and an aluminum clamp was machined to resist the torque required to open the vessel. The assembly of the pump, cooler, vessel, tubing, valves, and fittings can be found on pg. 26. While our design satisfies our specifications, some aspects of our system could be enhanced. It was determined that a wide and short vessel allows for better mixing of the scCO2 and oil. Also, we could have machined the cart to the exact size necessary to make it easier to maneuver. All major components of the system have been assembled. However, a few small components must still be ordered as seen in Table 3 on pg 33. Once this is completed, taping and turning tests should be conducted and compared to data from the previous system. Next, complete an analysis of the temperature gradients and create an algorithm for LabView. Then LabView can be used to automatically alert the user to refill the oil. Further testing can then be done to examine if this system could be used as a level sensor. In addition, experimentation should be done to determine the amount of time necessary for the system to equilibrate. If the time required to equilibrate is long, testing with an HPLC pump to provide continuous oil flow should be completed. Finally, conduct tests to compare use of one and two inlets of CO2 and its effect on the concentration of oil dissolving in scCO2. 2 TABLE OF CONTENTS EXECUTIVE SUMMARY..................................................................................................................2 INTRODUCTION................................................................................................................................4 PROJECT REQUIREMENTS AND ENGINEERING SPCEIFICATIONS .......................................4 Redesign the current system to produce a higher flow rate...........................................................4 Design a control to vary the flow rate ...........................................................................................5 Design a subsystem to deliver continuous oil flow to the pressure vessel ....................................5 Design a refill oil sensor in the pressure vessel. ............................................................................5 Design a method to “tune” the oil-scCO2 mixture.........................................................................5 CONCEPT GENERATION .................................................................................................................6 Redesign the current system to produce a higher flow rate ...........................................................7 Design a subsystem to deliver continuous oil flow to the pressure vessel ....................................7 Pressure Vessel Designs ................................................................................................................8 Design a refill oil sensor in the pressure vessel .............................................................................8 Design a method to “tune” the oil-scCO2 mixture.......................................................................11 CONCEPT SELECTION ...................................................................................................................12 Methods of concept selection ......................................................................................................12 Redesign the current system to produce a higher flow rate .........................................................12 Design a subsystem to deliver continuous oil flow to the pressure vessel ..................................13 Pressure Vessel Selection............................................................................................................14 Design a refill oil sensor in the pressure vessel ...........................................................................15 Design a method to “tune” the oil-scCO2 mixture ......................................................................17 PARAMETER ANALYSIS ...............................................................................................................17 Material Selection........................................................................................................................17 Design for Assembly ...................................................................................................................18 Design for Environmental Sustainability.....................................................................................18 Design for Safety.........................................................................................................................19 Manufacturing Process Selection.................................................................................................19 Redesign the current system to prouce a higher flow rate ...........................................................19 Pressure Vessel............................................................................................................................20 Design a refill oil sensor in the pressure vessel ...........................................................................21 Utility Cart...................................................................................................................................23 FINAL DESIGN.................................................................................................................................25 Redesign the current system to prouce a higher flow rate ..........................................................25 Pressure Vessel...........................................................................................................................26 Design a refill oil sensor in the pressure vessel..........................................................................26 FABRICATION PLAN......................................................................................................................26 Vessel mount fabrication ............................................................................................................26 Cart modification........................................................................................................................26 Cooler lid modification...............................................................................................................27 System Assembly .......................................................................................................................27 VALIDATION ...................................................................................................................................29 scCO2 - MWF.............................................................................................................................29 Design a refill oil sensor in the pressure vessel..........................................................................30 DISCUSSION ....................................................................................................................................32 RECOMMENDATIONS ...................................................................................................................33 CONCLUSION...................................................................................................................................34 ACKNLOWEDGEMENTS................................................................................................................35 INFORMATION SOURCES ..............................................................................................................35
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