Investigate The Effect of Different Regenerator Mesh Size On Cooling Capacity of Stirling Cryocooler

Investigate the effect of different Regenerator mesh size on cooling capacity of Stirling Cryocooler
1. INTRODUCTION
Cooling to the cryogenic temperatures has found applications in various diverging

fields, viz. space, military, civil applications, medical, food preservation, research in
basic sciences and bio-medical sciences for preservation of cells, to understand certain
phenomena which occur only in cryogenic range of temperatures viz.
superconductivity and super-fluidity etc. Production of low temperatures essential to
liquefy a gas, storage of the produced liquid cryogen, careful handling of the cryogenic
liquid, transfer lines essential for transferring the liquid etc. form a field of interest for
the researchers.
The Stirling cycle cryocoolers utilize linear motor as the drive for the piston and the
expander. This completely eliminates mechanical linkages essential for converting
rotary motion to linear motion as it directly produces linear motion.
A regenerator is a thermal storage material that periodically absorbs energy when

exposed to a hot fluid and releases it to the same fluid at a later stage in a cycle.
Thermodynamic cycles include regenerative heat transfer via a regenerator, in order to
attain low temperatures and high performance.
The regenerator is one of the key components of regenerative cryocoolers.

Regenerator loss caused by the defects in the regenerative matrix and its structure
accounts for a considerable proportion of the total losses.
The regenerator used in these cycles has a flow conduit that is filled with a porous
matrix having high surface area and heat capacity leading to large heat transfers. The
hot fluid entering at constant temperature, heats the matrix for half of the cycle, and
cold fluid cools the matrix for the second half of cycle while flowing in the reverse
direction, thus periodically heating and cooling the matrix while reversing the flow.
Since the first intuitive use of regenerator in the year 1816 by Robert Stirling in his
hot air engine, regenerative heat exchangers, based on this principle have evolved to
JSPM’S Jayawantrao Sawant College of Engineering, Pune – 28, BE (Mechanical Engineering)

Page 1
become one of the important components in achieving low temperatures in Cryogenic

Refrigerators or Cryocoolers. [4]
Fig. 1. Phosphor Bronze Regenerator Mesh

The performance of regenerator mesh directly affects the Cryocooler Performance. To
minimize the losses in regenerator mesh three parameters should be changed i.e. size,
material, packing geometry.
The efficiency of the regenerator is largely dependent upon the ratio of the volumetric
specific heat capacity of the regenerator matrix to that of helium.
Table No. 1 Requirements of a good Regenerator [3]

Sr. No. Requirements Solution
1. Maximum heat capacity Large solid matrix
2. Minimum flow losses Small porous matrix
3. Maximum heat transfer Finely divided matrix
4. Minimum contamination No obstruction

Page 2
Fig. 2. Cloth of Phosphor Bronze Mesh (300 – 49)
The regenerator with lower diameter in cold region and larger diameter in hot region
will lead to lower regenerator losses. Investigation of regenerator have been carried
out theoretically and will carry experimental further which has impact on performance
of Cryocooler.

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2. OBJECTIVES
 To study the performance characteristics of existing regenerator mesh (250 – 48).
 Cyclic analysis of regenerator mesh

a. Different types of regenerator material.
- Phosphor Bronze
- Stainless Steel
b. Different sizes of regenerator mesh.
- Regenerator mesh 250 – 48
- Regenerator mesh 300 – 49
c. To study effectiveness for different material and sizes.
 To manufacture displacer unit.

1. Displacer tube
2. Aluminum cap (Top)
3. Brass gas entry piece (Bottom)
 Experimental Testing
 Results with validation.

Page 4
3. METHODOLOGY
Modification of Existing Displacer

Unit (250 - 48)
Manufacturing of Displacer Parts
Testing and Parametric Analysis of

250 - 48 and 300 - 49 Mesh
Results, Comparison and Discussion
Conclusion

Page 5
4. LITERATURE REVIEW
Sr. No. Title Author Findings

1. A free-piston Stirling Alan Caughley, Metal diaphragm
cryocooler using metal Mathieu Sellier, pressure wave
diaphragms Michael generator used to move
Gschwendtner, Alan displacer without
Tucher rubbing and
Cryocooler has reached
56k and 77k with 29W
cooling power
2. Design and B. Jayaraman Heat conductivity of
optimization of (Indian Journal of phosphor bronze is
cryogenic regenerators Science and more than stainless
Technology, vol steel.
10(24), June 2017)
3. Thermal analysis of Sercan Ozbay Effect of different
Stirling cycle (The graduate school regenerator parameters
regenerator of natural and applied on cooling capacity.
science of the middle
east technical
university, August
2011)
4. Cryogenic Temperature S. Kar and R.G. Sharma Different cryogenic
sensor (Inter University temperature sensors used
Accelerator Centre, New to measure cryogenic
Delhi-110 067 Defence temperatures down to 1 K
Science Journal, Vol. 57, (K type).
No. 3, May 2007)

Page 6
5. REGENERATOR MESH PARAMETERS

The flow chart for the FORTRAN program is
Input Machine Data and Geometric Parameters
Calculate Live and Dead Volumes
Choose suitable Interval and Calculate values of

VC(1)...VC(13) ; VE(1)...VE(13)
Assume TC(1) and Use Dead Space temperature to Obtain

Value of P(1) , Assume MR = 1 and Adiabatic Compression
Find P(2).....P(13)
TC(1)=TC(13)
NO If ABS Values of
|P(1)-P(13)| &
|TC(1)-TC(13)|
With in Tolerance
YES
Find Pm and MR = (Pavg/Pm)

Multiply P(1).....P(13) to find out Actual Pressures
Calculate Mass Flow Rates for Various Intervals

over the Cycle
Calculate Ideal Power Input and Refrigerating Effect
Calculate Losses
Pact = PIdeal + Losses
REa = REIdeal - Losses
STOP
Fig. 3. Flow chart for Cyclic Analysis

Page 7
5.1. Displacer diameter:

The gap between the Cryo-cylinder and displacer is held constant. Further, the
thickness of the displacer (regenerator housed within) is also kept constant. Thus
change in displacer diameter also affects the regenerator diameter. This has been taken
into consideration.
Table No. 2. Net Refrigeration effect of Different Diameter of regenerator at 100 K
Pressure Pressure
Dia. of Net
Ideal RE Ideal drop in drop in Actual
regene Refrigerating
,W Power, W connecting regenerato power, W
rator effect, W
tube, W r,W
14 7.16 22.11 0.709 9.07 1.40 43.45

15 7.32 22.6 0.985 9.52 1.33 44.65
16 7.45 23.07 1.009 9.96 1.29 45.77
17 7.56 23.4 6.78E-01 10.40 1.30 46.84
18 7.66 23.75 2.85E-01 10.85 1.32 47.86
19 7.74 24.02 -1.66E-01 11.31 1.33 48.88
20 7.8 24.22 -6.18E-01 11.75 1.35 49.78
1.2
1
Net refrigeration, W
0.8
0.6
0.4
0.2
0
14 15 16 17 18 19
Regenerator diameter, mm
Graph No. 1. Net refrigeration effect for various diameter of regenerator

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5.2. Piston diameter:

For a fixed stroke of the opposed pistons, the mass flow rate in the system will be
increasing with increase in the diameter. For a desired average pressure, the system
may be in position to operate with lower charge pressure as the pressure ratio is
expected to increase.
5.3. Length of the regenerator:

With other parameters held fixed, the increase in the length of regenerator will lead to
improvement in effectiveness of regenerator. However, the increase in the pressure
drop across the regenerator will also increase the P-V loss. Increase in length, leading
to reduced temperature gradient, will also decrease the conduction
Table No. 3. Net Refrigeration effect of Different Length of regenerator at 100 K
Pressure
Net
Regenerator Ideal Ideal drop in
PV loss, W Refrigerating
length RE, W Power, W connecting
effect, W
tube, W
40 7.9 23.3 1.96 1.23 9.74
45 8.34 25.7 1.97 1.27 9.84
50 8.72 25.88 1.94 1.28 10.05
55 7.19 22.3 2.01 1.02 10.25
60 6.7 20.9 2.08 6.00E-01 10.4
1.4
Net refrigeration, W
1.2
0.8
0.6
0.4
0.2
0
40 45 50 55 60 65 70
Regenerator length, mm
Graph No. 2. Net Refrigeration effect of Different Length of regenerator

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5.4. Mesh size and wire diameter for regenerator:

Due to increased surface area available for finer mesh the regenerator ineffectiveness
loss can decrease substantially. However, the pressure drop will increase through the
regenerator. Once the effect of various geometric parameters is considered, the
geometric configuration to provide the best results is arrived. The unit can then be
fabricated. The wire diameter can be taken in the range of 0.01mm to 0.11mm. It
affects porosity, screen thickness and regenerator mass directly.
Table No. 4. Net Refrigeration effect on Different Mesh Size at 100 K
MESH SIZE 250 300 350

Ideal Refrigeration Effect,
8.9 9.76 10.85
W
Ideal Power, W 27.5 30.04 33.2
Net Refrigeration Effect, W 1.79 1.84 6.14E-01

Power Loss in Regenerator,
1.6 4.03 10.5
W
Additional Power Due
16.17 15.66 15.01
Pressure Drop in C- Tube
Actual Power, W 60.5 66.33 78.37
3
1
Net refrigeration
0
198 248 298 348 398
-1
-2
-3
-4
-5
-6
Mesh no.
Graph No. 3. Net refrigeration effect for various mesh size

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5.5. Number of screens:

This term sets the number of screens that will be stacked on the top of each other to
form the regenerator.
Fig. 4. Enlarge View of Regenerator Mesh [5]

Where,
D = Diameter of wire in micron
L = Length of square opening or pitch
5.6. Mesh density:

It defined as the no. of opening in screen disc. As an Industry standards, it is defined
as no. openings per sq. inch. Mesh density is related to the porosity. As density
increases porosity of mesh decreases and number of opening increases so that heat
capacity increases.
Graph No. 4. Effect of mesh density on porosity and inefficiency [1]

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5.7. Porosity:
It is defined as ratio of total volume of connected wide spaces to the total volume of
matrix. Mesh density has strong effect on porosity.
πDW√pitch × (2 + DW)
Porosity = 1 − ( )
4 × pitch
5.8. Effectiveness:
The effectiveness defines how well a real heat exchanger is performing relative to an
ideal exchanger operating across same temperature differences.
Q
ε=
Qactual
5.9. Regenerator Losses:

5.9.1. Regenerator Ineffectiveness:
In an ideal regenerator, the gas gets cooled from TC to TE considering 100 %
effectiveness. In actual regenerator, due to regenerator ineffectiveness gas gets cooled
from TC up to (TE+T), which is higher than the required temperature of TE.
A part of refrigerating effect is therefore lost at the expansion stages due to the
ineffectiveness of regenerator. This results in reduction in refrigerating effect. Proper
selection of the regenerator mesh of a material with high heat capacity in the operating
temperature range is essential for high effectiveness of the regenerator.
If the regenerator mesh is fine (high mesh number and small diameter) the required
large surface area will be available when densely packed and may give the desired
regenerator effectiveness.
However, this will result in excessive pressure drop when the gas passes through the
regenerator. Thus, the sum of the regenerator ineffectiveness loss and Pressure loss
needs to be minimized to provide maximum refrigerating effect at the desired
temperature.

Page 12
Fig. 5. Temperature variation in regenerator of Stirling cryocooler
5.9.2. Loss due to Temperature Swing:

This loss accounts for the temperature changes in the matrix of the regenerator during
the cycle. It is the heat taken up by the matrix due to its finite heat capacity. The
temperature swing loss is calculated for half cycle time i.e. during the forward motion
of the gas from compression space to the expansion space.
This loss should be considered only if the regenerator ineffectiveness loss is estimated
assuming the steady state conditions. However, if the regenerator analysis considers
the temperature variation of the matrix, there is no need to consider the swing loss
separately.
5.9.3. Pumping Loss:

A gap is provided between the cryo-cylinder and the displacer in order to avoid any
rubbing / friction between the two. The pumping loss is due to volume of this gap
between the displacer and the cryo-cylinder. The mass of gas in this volume at any
instant of time is dependent on the pressure in the system at that instance. At the
minimum pressure condition there is a minimum mass of gas in this clearance
volume.
Hence, the clearance between the displacer and the cryo-cylinder becomes a very
important parameter in determining the performance of the cryo-cooler. For the

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miniature cryo-cooler clearance of the order of 15 to 20 microns is preferred to reduce

the pumping loss.
When the displacer moves towards cold end, comparatively hot gas pressurises this
gap volume and when the displacer moves away from the cold end (during expansion),
this gas enters the expansion space and picks up some cooling effect thus resulting in
loss. This loss is called as the pumping loss.
5.9.4. Loss due to Conduction:

This loss is independent of the machine speed. It is simply the heat transferred
between the hot and cold ends of the following components.
(i) Displacer Material
(ii) Cryo-cylinder
(iii) Regenerator Matrix Material
Usually, the regenerator of Stirling cryocooler is made up of layers of fine screens

that are tightly packed or sintered together.
Effective thermal conductivity of the regenerator matrix, Kmx is given by Martini [9]
(1  K m / K g )
 FF
(1  K m / K g )
K mx  K G
(1  K m / K g )
 FF
(1  K m / K g )
where,
FF = Fill factor = (1- Porosity), for the mesh.
The loss is then calculated by simple conduction formula considering the cross-
sectional area of the regenerator matrix,
T
Qcmx  K mx * AR *
LR
Expressions can be utilized by considering the conductivity, area, temperature
difference and the length of the regenerator

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6. DEVELOPMENT OF THE DISPLACER UNIT
The expander unit consists of a displacer suspended on two stacks of flexure bearings
and reciprocating inside the Cryo-cylinder. The central hole of the main body
accommodating the displacer shaft separates the working space from the bounce space
inside the end cover. Clearance of the order of 12 to 15 microns is kept between the
shaft portion (pasted with Rulon) inside the central hole with the hole to avoid
working gas leaking to the expander bounce space. The nominal stroke of the displacer
is 3 mm. The required drive is provided by a moving coil linear motor.
Table No. 5 Part list of Displacer Unit

Sr. No. Part Material Qty.
1. Main Body Aluminium 1
2. Top pole piece Permandur 1
3. Magnet Nd-Fe-B 1
4. Bush Brass 1
5. Flexure support ring Aluminium 1
6. Shaft SS–304 1
7. Inner spacer Aluminium 8
8. Long spacer Aluminium 1
9. Outer spacer Aluminium 8
10. Cryo-cylinder flange (Top cover) Aluminium 1
11. Coil former Aluminium 1
12. Flexure disc Beryllium copper 8
13. Integrated one-stage Displacer tube SS-304 1
14. Cryo-cylinder tube SS-304 1
15. Entry cap Brass 1
16. Displacer pipe SS-304 1
17. End Cover Aluminium 1

Page 15
Fig. 6. Schematic diagram of opposed piston Stirling cryocooler
Fig. 7. Assembled Displacer tube with brass entry cap and Aluminium end cover

Page 16
Fig. 8. Displacer Pipe
Fig. 9. Aluminium End Cover

Page 17
Fig. 10. Entry Cap
Fig. 11. Main Body

Page 18
Fig. 12. Cryo – Cylinder
Fig. 13. Total Vacuum Jacket

Page 19
Fig. 14. Perspex Vacuum Cover
Fig. 15. Expander Shaft

Page 20
7. REGENERATOR MATERIALS
The regenerator material is selected in such a way that its heat capacity must be larger
than that of working gas. Based on the temperature range in which the regenerators
operate, its design and analysis can be divided into two main groups.
The first group is the efforts to find the optimum regenerator from 300 K to 30 K and
the second is the research below 30 K. The first group from 300 K to 30 K are the
Stainless steel and copper alloy materials which are ductile and can be woven into
screen meshes. Erbium, Neodymium and other rare earth alloys have been developed
as regenerator materials.
Table No. 6. Properties of Materials (Approximate)

Sr. No. Parameters Stainless steel Phosphor Bronze
1. Copper Contain 3 to 5 % 85 to 90 %
2. Thermal Conductivity 12 – 45 w/mk Above 46 w/mk
3. Specific heat capacity 480 J/kg-k 380 J/kg-k
4. Thermal Expansion 17 µm/m-K 18 µm/m-K
5. Young's Modulus 200 GPa 110 GPa
6. Poisson's Ratio 0.28 0.34
7. Electrical Conductivity 2.4 % 18 %
8. Density 7.8 g/cm3 8.8 g/cm3
Research on regenerator materials below 30 K is experimental in nature as theories

predicting the transition temperature and heat capacity of an alloy or intermetallic
compound are lacking and materials are discovered by intuition or trial and error.
Therefore, extensive studies on search of materials or combination of them with higher
performance have been carried out.

Page 21
Graph No. 5. Specific heat and heat conductivity of Stainless Steel, Phosphor
bronze [3]
7.1. Feature of phosphor bronze wire mesh
 Corrosion, wear, tear, rust, fatigue, acid and alkali resistance.

 Non-magnetic, good ductility, high toughness, high strength.
 Good electricity and heat conductivity.
 Phosphor copper wire mesh with higher copper content makes it more
corrosion resistance than brass mesh cloth. It is harder and stronger than copper
mesh cloth.

Page 22
8. EXPERIMENTAL WORK
The Compressor and Displacer unit was connected by a copper tube. Initially the
Cryo-cooler unit was charged with 16 bar of Helium gas as a working fluid few leaks
were detected and prevented by adhesive. After preventing all leaks the Cryo-cooler
unit was connected with two channel power supply and a high order vacuum pump to
prevent various losses.
Two channel power supply is used to maintain the required frequency and phase shift
between the compressor and displacer unit. It consists of two channel supply of 1KVA
& 50VA with arrangement to maintain a phase shift between compressor and expander
unit from -180 to +180 degrees. Also provision is provided to vary the operating
frequency. Vacuum of the order 10-6 mbar was maintained in the vacuum chamber to
prevent the convection losses with the help of high Vacuum pump.
Fig. 16. Experimental Setup

Page 23
Fig. 17. Complete assembled Cryo-cooler and Displacer sectional view

Page 24
9. RESULTS:
Following observation was recorded during the experimental testing
9.1. Results of 250 – 48 Mesh:

Table No. 7. Result Analysis of 250 – 48 Mesh at 15 bar
Charge pressure = 15 bar, Frequency = 50 Hz
Comp Comp Exp Exp Phase
Time
voltage current voltage current shift Temp
(min)
(volt) (Amp) (volt) (Amp) (degree) (°C)
65 2.12 5.5 1.39 68 30 0
65 2.12 5.5 1.39 68 17 2
65 2.12 5.5 1.39 68 5 4
65 2.12 5.5 1.39 68 0 6
65 2.12 5.5 1.39 68 -9 8
65 2.12 5.5 1.39 68 -20 10
65 2.12 5.5 1.39 68 -28 12
65 2.12 5.5 1.39 68 -39 14
65 2.12 5.5 1.39 68 -52 16
65 2.12 5.5 1.39 68 -65 18
65 2.12 5.5 1.39 68 -73 20
65 2.12 5.5 1.39 68 -80 22
65 2.12 5.5 1.39 68 -90 24
65 2.12 5.5 1.39 68 -90 26
65 2.12 5.5 1.39 68 -100 28
65 2.12 5.5 1.39 68 -110 30
65 2.12 5.5 1.39 68 -110 32
75 2.41 6 1.66 68 -115 34
75 2.41 6 1.66 68 -121 36
75 2.41 6 1.66 68 -126 38
75 2.41 6 1.66 68 -130 40
75 2.41 6 1.66 68 -130 42

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75 2.41 6 1.66 68 -132 44

75 2.41 6 1.66 68 -132 46
80 2.55 6.5 1.77 68 -140 48
80 2.55 6.5 1.77 68 -140 50
80 2.55 6.5 1.77 68 -146 52
80 2.55 6.5 1.77 68 -151 54
80 2.55 6.5 1.77 68 -160 56
80 2.55 6.5 1.77 68 -160 58
80 2.55 6.5 1.77 68 -172 60
80 2.55 6.5 1.77 68 -175 62
The Graph 6 below shows the cooling curve distribution with time were minimum
temperature reached was -175 degree Celsius.
Temperature vs Time curve

50
0
0 10 20 30 40 50 60 70
Temperature (C°)
-50
-100
-150
-200
Time (minutes)
Graph No. 6. Cooling distribution curve 200 Mesh (15 Bar)

Page 26

Time
(min)
60 1.91 3.7 0.99 84 32 0
60 1.91 3.7 0.99 84 15 1
60 1.91 3.7 0.99 84 0 2
60 1.91 3.7 0.99 84 -8 3
60 1.91 3.7 0.99 84 -18 4
60 1.91 3.7 0.99 84 -36 5
60 1.91 3.7 0.99 84 -51 6
60 1.91 3.7 0.99 84 -54 8
60 1.91 3.7 0.99 84 -57 11
60 1.91 3.7 0.99 84 -63 14
60 1.91 3.7 0.99 84 -67 17
60 1.91 3.7 0.99 84 -70 18
60 1.91 3.7 0.99 84 -73 19
60 1.91 3.7 0.99 84 -77 20
60 1.91 3.7 0.99 84 -80 22
60 1.91 3.7 0.99 84 -84 24
60 1.91 3.7 0.99 84 -87 26
60 1.91 3.7 0.99 84 -91 28
60 1.91 3.7 0.99 84 -94 32
60 1.91 3.7 0.99 84 -98 35
60 1.91 3.7 0.99 84 -102 38
60 1.91 3.7 0.99 84 -106 42
60 1.91 3.7 0.99 84 -110 46
69 2.43 3.7 0.99 84 -115 47
69 2.43 3.7 0.99 84 -118 49
69 2.43 3.7 0.99 84 -122 51
69 2.43 4.9 1.2 84 -127 57

Page 27
69 2.43 4.9 1.2 87 -131 78

69 2.43 4.9 1.2 95 -136 89
69 2.43 4.9 1.2 110 -141 90
69 2.43 4.9 1.2 125 -146 105
69 2.43 6.1 1.5 125 -151 110
69 2.43 6.1 1.5 125 -163 115
69 2.43 6.1 1.5 125 -178 120
80 2.43 6.1 1.5 125 -183 130
80 2.54 6.1 1.5 130 -191 140

50
0
0 20 40 60 80 100 120 140 160
Temperature (C°)
-50
-100
-150
-200
-250
Time (minutes)
Graph No. 7. Cooling distribution curve 200 Mesh (16 Bar)

Page 28

Time
(min)
65 2.08 5.5 1.52 68 34 0
65 2.08 5.5 1.52 68 20 2
65 2.08 5.5 1.52 68 8 4
65 2.08 5.5 1.52 68 -4 6
65 2.08 5.5 1.52 68 -11 8
65 2.08 5.5 1.52 68 -19 10
65 2.08 5.5 1.52 68 -27 12
65 2.08 5.5 1.52 68 -39 14
65 2.08 5.5 1.52 68 -46 16
65 2.08 5.5 1.52 68 -51 18
65 2.08 5.5 1.52 68 -71 20
65 2.08 5.5 1.52 68 -86 22
65 2.08 5.5 1.52 68 -99 24
65 2.08 5.5 1.52 68 -109 26
75 2.41 6 1.66 68 -123 28
75 2.41 6 1.66 68 -134 30
75 2.41 6 1.66 68 -141 32
75 2.41 6 1.66 68 -146 34
75 2.41 6 1.66 68 -154 36
75 2.41 6 1.66 68 -159 38
80 2.55 6 1.66 68 -163 40
80 2.55 6 1.66 68 -173 42
80 2.55 6 1.66 68 -178 44
80 2.55 6 1.66 68 -178 46
80 2.55 6 1.66 68 -180 48
80 2.55 6 1.66 68 -183 50
85 2.68 6.5 1.74 68 -186 52

Page 29
85 2.68 6.5 1.74 68 -186 54

85 2.68 6.5 1.74 68 -188 56
85 2.68 6.5 1.74 68 -190 60
85 2.68 6.5 1.74 68 -193 64
85 2.68 6.5 1.74 68 -197 68
85 2.68 6.5 1.74 68 -198 72
85 2.68 6.5 1.74 68 -201 76
85 2.68 6.5 1.74 68 -203 80
85 2.68 6.5 1.74 68 -205 88

50
0
0 20 40 60 80 100
Temperature (C°)
-50
-100
-150
-200
-250
Time (minutes)
Graph No. 8. Cooling distribution curve of 200 Mesh (17 Bar)

Page 30
9.2. Results of 300 – 49 Mesh:

Time
(min)
65 2.08 5.5 1.52 68 29 0
65 2.08 5.5 1.52 68 13 2
65 2.08 5.5 1.52 68 3 5
65 2.08 5.5 1.52 68 -9 8
65 2.08 5.5 1.52 68 -13 11
65 2.08 5.5 1.52 68 -19 14
65 2.08 5.5 1.52 68 -25 17
65 2.08 5.5 1.52 68 -31 20
65 2.08 5.5 1.52 68 -38 23
65 2.08 5.5 1.52 68 -44 26
65 2.08 5.5 1.52 68 -47 28
65 2.08 5.5 1.52 68 -56 30
65 2.08 5.5 1.52 68 -61 32
65 2.08 5.5 1.52 68 -67 34
65 2.08 5.5 1.52 68 -70 36
65 2.08 5.5 1.52 68 -73 38
70 2.25 6 1.66 68 -77 40
70 2.25 6 1.66 68 -82 42
70 2.25 6 1.66 68 -86 44
70 2.25 6 1.66 68 -89 46
70 2.25 6 1.66 68 -89 48
75 2.41 6.5 1.74 68 -95 50
75 2.41 6.5 1.74 68 -102 52
75 2.41 6.5 1.74 68 -105 54
75 2.41 6.5 1.74 68 -108 56

Page 31
75 2.41 6.5 1.74 68 -112 58

80 2.55 6.5 1.74 68 -115 62
80 2.55 6.5 1.74 68 -119 66
80 2.55 6.5 1.74 68 -122 70
80 2.55 6.5 1.74 68 -126 74
80 2.55 6.5 1.74 68 -126 78
85 2.68 80 2.55 6.5 -130 82
85 2.68 80 2.55 6.5 -133 86
85 2.68 80 2.55 6.5 -133 90
85 2.68 80 2.55 6.5 -137 94
85 2.68 80 2.55 6.5 -142 98
85 2.68 80 2.55 6.5 -142 102
85 2.68 80 2.55 6.5 -145 106

40
20
0
Temperature (C°)
-20 0 20 40 60 80 100 120

-40
-60
-80
-100
-120
-140
-160
Time (minutes)

Page 32

Time
(min)
34 1.17 4.4 0.96 82 28 0
34 1.17 4.4 0.96 82 9 1
34 1.17 4.4 0.96 82 -6 2
34 1.17 4.4 0.96 82 -15 3
34 1.17 4.4 0.96 82 -24 4
34 1.17 4.4 0.96 82 -33 5
34 1.17 4.4 0.96 82 -41 6
34 1.17 4.4 0.96 82 -49 7
34 1.17 4.4 0.96 82 -56 8
34 1.17 4.4 0.96 82 -68 10
34 1.17 4.4 0.96 82 -77 12
34 1.17 4.4 0.96 82 -77 14
40 1.44 5 1.26 82 -92 16
40 1.44 5 1.26 82 -99 18
40 1.44 5 1.26 82 -99 20
50 1.68 5.5 1.4 82 -112 22
50 1.68 5.5 1.4 82 -115 24
60 2.02 6 1.55 82 -126 26
60 2.02 6 1.55 82 -130 28
70 2.29 6.5 1.70 82 -138 30
70 2.29 6.5 1.70 82 -142 32
70 2.29 6.5 1.70 82 -146 34
80 2.59 7.0 1.84 82 -159 36
80 2.59 7.0 1.84 82 -178 38
80 2.59 7.0 1.84 82 -178 40
80 2.59 7.0 1.84 82 -183 42
85 2.65 7.5 1.96 82 -189 46

Page 33
85 2.65 7.5 1.96 82 -195 50

85 2.65 7.5 1.96 82 -201 54
85 2.65 7.5 1.96 82 -209 58
85 2.65 7.5 1.96 82 -216 62
85 2.65 7.5 1.96 82 -216 64
85 2.65 7.5 1.96 82 -216 66
85 2.65 7.5 1.96 82 -216 68
85 2.65 7.5 1.96 82 -216 70

50
0
0 10 20 30 40 50 60 70 80
Temperature (C°)
-50
-100
-150
-200
-250
Time (minutes)

Page 34
9.3. Comparison Between (250 – 48) and (300 – 49) Mesh:
Comparison Between (250 – 48) and (300 – 49) Mesh
50
0
0 20 40 60 80 100
-50
Temperature
-100
-150
-200
-250
Time
250 300
Graph No. 11. Comparison Between (250 – 48) and (300 – 49) Mesh
Fig. 18. Sequential Operation of Vacuum Fig. 19. Temperature

pump Measurement

Page 35
10. APPLICATIONS:
1. Cooling of IR sensors:
Cooled detectors are typically contained in a vacuum-sealed case
and cryogenically cooled. The cooling is necessary for the operation of the
semiconductor materials used. Typical operating temperatures range from
4 K to just below room temperature, depending on the detector technology.
Most modern cooled detectors operate in the 60 K to 100 K range, depending
on type and performance level. [9]
2. Liquefication of Gas:
The liquefaction of gases is a complicated process that uses various
compressions and expansions to achieve high pressures and very low
temperatures.
At ambient pressure the boiling point of liquefied helium is 4.22 K
(−268.93 °C). Below 2.17 K liquid He becomes a superfluid [10]
10.1. Future scope:
Effect on cooling performance with variation in parameters like regenerator mesh size,
number of screens, wire diameter, mesh density, etc.

Page 36
11. CONCLUSION:
It has been concluded that the Cryo-cooler tip has recorded a minimum temperature of
-216 degree Celsius with a power input of both the unit 246 Watt. Compressor unit
requires 230W of power and 16W for the expander unit. A mechanical phase shift of
60 to 84 degree was maintained between the compressor and expander unit where
expander leads the compressor unit.
Phase shift plays a key role in the cooling of Stirling cycle Cryo-cooler. To get the
optimum cooling phase shift between the two units its needed to be fine tuned.
Operating frequency was kept at 50Hz. It was also known that proper assembly of the
compressor unit and displacer unit plays an important role in the performance of the
system.
Further the effect on cooling performance with variation in charge pressure to

compressor is needed to be done. Provision is needed to measure the mass flow rate at
outlet of the opposed piston linear compressor.
Flexure bearing of thickness more than 0.7mm should be tried to avoid the failure of
the flexure bearing. Need to make provision for the measurement of mass flow rate
experimentally in compression space and expansion space.

Page 37
REFERENCES
 Thesis:
1. “Thermal analysis of Stirling cycle regenerator” by Sercan Ozbay, The graduate
school of natural and applied science of the middle east technical university, August
2011.
2. “Low Temperature Cryocooler Regenerator Materials” by K. A. Gschneidner, A. O.
Percharsky and V. K. Percharsky, Ames Laboratory and Department of Materials
Science and Engineering Iowa State University, Ames, Iowa 50011 – 3020, USA.
 Journals:
1. “Design and optimization of cryogenic regenerators” by B. Jayaraman, Indian
Journal of Science and Technology, vol 10(24), June 2017.
2. “Cryogenic Regenerative Heat Exchanger” by Ackerman RA., New York, Plenum
Press; 1997
 External Links:
 https://nptel.ac.in/downloads/112101004/
 http://www.rajfilters.com/ss-wire-mesh-manufacturers/
 https://en.wikipedia.org/wiki/Liquefaction_of_gases#Linde's_process
 https://www.makeitfrom.com/compare/AISI-316-S31600-Stainless-Steel/UNS-
C52100-CW453K-Phosphor-Bronze

Page 38

Investigate The Effect of Different Regenerator Mesh Size On Cooling Capacity of Stirling Cryocooler

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Investigate The Effect of Different Regenerator Mesh Size On Cooling Capacity of Stirling Cryocooler

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Investigate the effect of different Regenerator mesh size on cooling capacity of Stirling Cryocooler

Cooling to the cryogenic temperatures has found applications in various diverging

A regenerator is a thermal storage material that periodically absorbs energy when

The regenerator is one of the key components of regenerative cryocoolers.

JSPM’S Jayawantrao Sawant College of Engineering, Pune – 28, BE (Mechanical Engineering)

become one of the important components in achieving low temperatures in Cryogenic

Fig. 1. Phosphor Bronze Regenerator Mesh

Table No. 1 Requirements of a good Regenerator [3]

JSPM’S Jayawantrao Sawant College of Engineering, Pune – 28, BE (Mechanical Engineering)

Fig. 2. Cloth of Phosphor Bronze Mesh (300 – 49)

JSPM’S Jayawantrao Sawant College of Engineering, Pune – 28, BE (Mechanical Engineering)

 To study the performance characteristics of existing regenerator mesh (250 – 48).

 Cyclic analysis of regenerator mesh

 To manufacture displacer unit.

 Results with validation.

JSPM’S Jayawantrao Sawant College of Engineering, Pune – 28, BE (Mechanical Engineering)

Modification of Existing Displacer

Manufacturing of Displacer Parts

Testing and Parametric Analysis of

Results, Comparison and Discussion

JSPM’S Jayawantrao Sawant College of Engineering, Pune – 28, BE (Mechanical Engineering)

Sr. No. Title Author Findings

JSPM’S Jayawantrao Sawant College of Engineering, Pune – 28, BE (Mechanical Engineering)

5. REGENERATOR MESH PARAMETERS

Input Machine Data and Geometric Parameters

Calculate Live and Dead Volumes

Choose suitable Interval and Calculate values of

Assume TC(1) and Use Dead Space temperature to Obtain

Find Pm and MR = (Pavg/Pm)

Calculate Mass Flow Rates for Various Intervals

Calculate Ideal Power Input and Refrigerating Effect

Fig. 3. Flow chart for Cyclic Analysis

JSPM’S Jayawantrao Sawant College of Engineering, Pune – 28, BE (Mechanical Engineering)

5.1. Displacer diameter:

Table No. 2. Net Refrigeration effect of Different Diameter of regenerator at 100 K

14 7.16 22.11 0.709 9.07 1.40 43.45

Graph No. 1. Net refrigeration effect for various diameter of regenerator

JSPM’S Jayawantrao Sawant College of Engineering, Pune – 28, BE (Mechanical Engineering)

5.2. Piston diameter:

5.3. Length of the regenerator:

Table No. 3. Net Refrigeration effect of Different Length of regenerator at 100 K

Graph No. 2. Net Refrigeration effect of Different Length of regenerator

JSPM’S Jayawantrao Sawant College of Engineering, Pune – 28, BE (Mechanical Engineering)

5.4. Mesh size and wire diameter for regenerator:

Table No. 4. Net Refrigeration effect on Different Mesh Size at 100 K

MESH SIZE 250 300 350

Net Refrigeration Effect, W 1.79 1.84 6.14E-01

JSPM’S Jayawantrao Sawant College of Engineering, Pune – 28, BE (Mechanical Engineering)

5.5. Number of screens:

Fig. 4. Enlarge View of Regenerator Mesh [5]

5.6. Mesh density:

Graph No. 4. Effect of mesh density on porosity and inefficiency [1]

JSPM’S Jayawantrao Sawant College of Engineering, Pune – 28, BE (Mechanical Engineering)

5.9. Regenerator Losses:

JSPM’S Jayawantrao Sawant College of Engineering, Pune – 28, BE (Mechanical Engineering)

Fig. 5. Temperature variation in regenerator of Stirling cryocooler

5.9.2. Loss due to Temperature Swing:

5.9.3. Pumping Loss:

JSPM’S Jayawantrao Sawant College of Engineering, Pune – 28, BE (Mechanical Engineering)

miniature cryo-cooler clearance of the order of 15 to 20 microns is preferred to reduce

5.9.4. Loss due to Conduction:

Usually, the regenerator of Stirling cryocooler is made up of layers of fine screens

JSPM’S Jayawantrao Sawant College of Engineering, Pune – 28, BE (Mechanical Engineering)