Search results for: roll forming die design

Authors: A. Saha Chaudhuri, D. Sarkar

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In steel construction, there are two families of structural members. One is hot rolled steel and another is cold formed steel. Cold formed steel section includes steel sheet, strip, plate or flat bar. Cold formed steel section is manufactured in roll forming machine by press brake or bending operation. Cold formed steel (CFS), also known as Light Gauge Steel (LGS). As cold formed steel is a sustainable material, it is widely used in green building. Cold formed steel can be recycled and reused with no degradation in structural properties. Cold formed steel structures can earn credits for green building ratings such as LEED and similar programs. Cold formed steel construction satisfies international demand for better, more efficient and affordable buildings. Cold formed steel sections are used in building, car body, railway coach, various types of equipment, storage rack, grain bin, highway product, transmission tower, transmission pole, drainage facility, bridge construction etc. Various shapes of cold formed steel sections are available, such as C section, Z section, I section, T section, angle section, hat section, box section, square hollow section (SHS), rectangular hollow section (RHS), circular hollow section (CHS) etc. In building construction cold formed steel is used as eave strut, purlin, girt, stud, header, floor joist, brace, diaphragm and covering for roof, wall and floor. Cold formed steel has high strength to weight ratio and high stiffness. Cold formed steel is non shrinking and non creeping at ambient temperature, it is termite proof and rot proof. CFS is durable, dimensionally stable and non combustible material. CFS is economical in transportation and handling. At present days cold formed steel becomes a competitive building material. In this paper all these applications related present research work are described and how the CFS can be used as blast resistant structural system that is examined.

Keywords: cold form steel sections, applications, present research review, blast resistant design

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Authors: Piotr Jerzy Rugor, Julia Wajoras

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The presented work regards a single-stage aerodynamically controlled solid propulsion rocket. Steering a rocket to fly along a predetermined trajectory can be beneficial for minimizing aerodynamic losses and achieved by implementing an active control system on board. In this particular case, a canard configuration has been chosen, although other methods of control have been considered and preemptively analyzed, including non-aerodynamic ones. The objective of this work is to create a system capable of guiding the rocket, focusing on roll stabilization. The paper describes initial analysis of the problem, covers the main challenges of missile guidance and presents data acquired during the experimental study.

Keywords: active canard control system, rocket design, numerical simulations, flight optimization

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Authors: Muhamad Sani Buang, Shahrul Azam Abdullah, Juri Saedon

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There is not much effective guideline on development of design parameters selection on springback for advanced high strength steel sheet metal in U-channel process during cold forming process. This paper presents the development of predictive model for springback in U-channel process on advanced high strength steel sheet employing Response Surface Methodology (RSM). The experimental was performed on dual phase steel sheet, DP590 in U-channel forming process while design of experiment (DoE) approach was used to investigates the effects of four factors namely blank holder force (BHF), clearance (C) and punch travel (Tp) and rolling direction (R) were used as input parameters using two level values by applying Full Factorial design (24). From a statistical analysis of variant (ANOVA), result showed that blank holder force (BHF), clearance (C) and punch travel (Tp) displayed significant effect on springback of flange angle (β2) and wall opening angle (β1), while rolling direction (R) factor is insignificant. The significant parameters are optimized in order to reduce the springback behavior using Central Composite Design (CCD) in RSM and the optimum parameters were determined. A regression model for springback was developed. The effect of individual parameters and their response was also evaluated. The results obtained from optimum model are in agreement with the experimental values

Keywords: advance high strength steel, u-channel process, springback, design of experiment, optimization, response surface methodology (rsm)

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Authors: Mostafa Mjahed

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This paper concerns the control of a nonlinear system using two different methods, reference model and genetic algorithm. The quadcopter is a nonlinear unstable system, which is a part of aerial robots. It is constituted by four rotors placed at the end of a cross. The center of this cross is occupied by the control circuit. Its motions are governed by six degrees of freedom: three rotations around 3 axes (roll, pitch and yaw) and the three spatial translations. The control of such system is complex, because of nonlinearity of its dynamic representation and the number of parameters, which it involves. Numerous studies have been developed to model and stabilize such systems. The classical PID and LQ correction methods are widely used. If the latter represent the advantage to be simple because they are linear, they reveal the drawback to require the presence of a linear model to synthesize. It also implies the complexity of the established laws of command because the latter must be widened on all the domain of flight of these quadcopter. Note that, if the classical design methods are widely used to control aeronautical systems, the Artificial Intelligence methods as genetic algorithms technique receives little attention. In this paper, we suggest comparing two PID design methods. Firstly, the parameters of the PID are calculated according to the reference model. In a second phase, these parameters are established using genetic algorithms. By reference model, we mean that the corrected system behaves according to a reference system, imposed by some specifications: settling time, zero overshoot etc. Inspired from the natural evolution of Darwin's theory advocating the survival of the best, John Holland developed this evolutionary algorithm. Genetic algorithm (GA) possesses three basic operators: selection, crossover and mutation. We start iterations with an initial population. Each member of this population is evaluated through a fitness function. Our purpose is to correct the behavior of the quadcopter around three axes (roll, pitch and yaw) with 3 PD controllers. For the altitude, we adopt a PID controller.

Keywords: quadcopter, genetic algorithm, PID, fitness, model, control, nonlinear system

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Authors: A. H. Elkholy, D. M. Almutairi

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The successful and efficient execution of a forging process is dependent upon the correct analysis of loading and metal flow of blanks. This paper investigates the Upper Bound Technique (UBT) and its application in the analysis of open forging process when a possibility of blank bulging exists. The UBT is one of the energy rate minimization methods for the solution of metal forming process based on the upper bound theorem. In this regards, the kinematically admissible velocity field is obtained by minimizing the total forging energy rate. A computer program is developed in this research to implement the UBT. The significant advantages of this method is the speed of execution while maintaining a fairly high degree of accuracy and the wide prediction capability. The information from this analysis is useful for the design of forging processes and dies. Results for the prediction of forging loads and stresses, metal flow and surface profiles with the assured benefits in terms of press selection and blank preform design are outlined in some detail. The obtained predictions are ready for comparison with both laboratory and industrial results.

Keywords: forging, upper bound technique, metal forming, forging energy, forging die/platen

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Authors: C. Guven, M. Tufekci, E. Bayik, O. Gedik, M. Tas

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A sliding door system is used in commercial vehicles and passenger cars to allow a larger unobstructed access to the interior for loading and unloading. The movement of a sliding door on vehicle body is ensured by mechanisms and tracks having special cross-section which is manufactured by roll forming and stretch bending process. There are three tracks and three mechanisms which are called upper, central and lower on a sliding door system. There are static requirements as strength on different directions, rigidity for mechanisms, and door drop off, door sag; dynamic requirements as high energy slam opening-closing and durability requirement to validate these products. In addition, there is a kinematic requirement to find out force values from door handle during manual operating. In this study, finite element analysis and physical test results which are realized for sliding door systems will be shared comparatively.

Keywords: finite element analysis, sliding door, experimental, verification, vehicle tests

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Authors: Maziar Ramezani, Thomas Neitzert, Timotius Pasang

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This paper aims at experimental and numerical investigation of springback behavior of sheet metals during L-bending process with emphasis on Stribeck-type friction modeling. The coefficient of friction in Stribeck curve depends on sliding velocity and contact pressure. The springback behavior of mild steel and aluminum alloy 6022-T4 sheets was studied experimentally and using numerical simulations with ABAQUS software with two types of friction model: Coulomb friction and Stribeck friction. The influence of forming speed on springback behavior was studied experimentally and numerically. The results showed that Stribeck-type friction model has better results in predicting springback in sheet metal forming. The FE prediction error for mild steel and 6022-T4 AA is 23.8%, 25.5% respectively, using Coulomb friction model and 11%, 13% respectively, using Stribeck friction model. These results show that Stribeck model is suitable for simulation of sheet metal forming especially at higher forming speed.

Keywords: friction, L-bending, springback, Stribeck curves

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Authors: James S. Kwame, E. Yakushina, P. Blackwell

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The challenges in forming titanium alloys at room temperature are well researched and are linked both to the limitations imposed by the basic crystal structure and their ability to form texture during plastic deformation. One major issue of concern for the sheet forming of titanium alloys is their high sensitivity to surface inhomogeneity. Various machining processes are utilised in preparing sheet hole edges for edge flanging applications. However, the response of edge forming tendencies of titanium to different edge surface finishes is not well investigated. The hole expansion test is used in this project to elucidate the impact of abrasive water jet (AWJ) and electro-discharge machining (EDM) cutting techniques on the edge formability of CP-Ti (Grade 2) and Ti-3Al-2.5V alloys at room temperature. The results show that the quality of the edge surface finish has a major effect on the edge formability of the materials. The work also found that the variations in the edge forming performance are mainly the result of the influence of machining induced edge surface defects.

Keywords: titanium alloys, hole expansion test, edge formability, non-conventional machining

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Authors: M. J. Davidson, N. Selvaraj, L. Venugopal

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The elevated temperature forming studies on the expansion of thin walled tubes have been studied in the present work. The influence of process parameters namely the die angle, the die ratio and the operating temperatures on the expansion of tube ends at elevated temperatures is carried out. The range of operating parameters have been identified by perfoming extensive simulation studies. The hot forming parameters have been evaluated for AA2014 alloy for performing the simulation studies. Experimental matrix has been developed from the feasible range got from the simulation results. The design of experiments is used for the optimization of process parameters. Response Surface Method’s (RSM) and Box-Behenken design (BBD) is used for developing the mathematical model for expansion. Analysis of variance (ANOVA) is used to analyze the influence of process parameters on the expansion of tube ends. The effect of various process combinations of expansion are analyzed through graphical representations. The developed model is found to be appropriate as the coefficient of determination value is very high and is equal to 0.9726. The predicted values are found to coincide well with the experimental results, within acceptable error limits.

Keywords: expansion, optimization, Response Surface Method (RSM), ANOVA, bbd, residuals, regression, tube

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Authors: Basavaraj Vadavadagi, Satishkumar Shekhawat

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Interstitial free steels posses better formability and have many applications in automotive industries. Forming limit diagrams (FLDs) indicate the formability of materials which can be determined by experimental and finite element (FE) simulations. FLDs were determined experimentally by LDH test, utilizing optical strain measurement system for measuring the strains in different width specimens and by FE simulations in Interstitial Free (IF) and Interstitial Free High Strength (IFHS) steels. In this study, the experimental and FE simulated FLDs are compared and also the stress based FLDs were investigated.

Keywords: forming limit diagram, limiting dome height, optical strain measurement, interstitial

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Authors: Ji-Seok Hong, Hee-Jang Moon, Hong-Gye Sung

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The details of flow structures and the coupling mechanism between vortex shedding and acoustic excitation in a solid rocket motor with two inhibitors have been investigated using 3D Large Eddy Simulation (LES) and Proper Orthogonal Decomposition (POD) analysis. The oscillation frequencies and vortex shedding periods from two inhibitors compare reasonably well with the experimental data and numerical result. A total of four different locations of the rear inhibitor has been numerically tested to characterize the coupling relation of vortex shedding frequency and acoustic mode. The major source of triggering pressure oscillation in the combustor is the resonance with the acoustic longitudinal half mode. It was observed that the counter-rotating vortices in the nozzle flow produce roll torque.

Keywords: large eddy simulation, proper orthogonal decomposition, SRM instability, flow-acoustic coupling

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Authors: K. Eshwara Prasad, R. Raman Goud, Swadesh Kumar Singh, N. Sateesh

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In the present work forming limit diagrams and strain distribution profile diagrams for extra deep drawing steel at room and elevated temperatures have been determined experimentally by conducting stretch forming experiments by using designed and fabricated warm stretchforming tooling setup. With the help of forming Limit Diagrams (FLDs) and strain distribution profile diagrams the formability of Extra Deep Drawing steel has been analyzed and co-related with mechanical properties like strain hardening COEFFICIENT (n) and normal anisotropy (r−).Mechanical properties of EDD steel from room temperature to 4500C were determined and discussed the impact of temperature on the properties like work hardening exponent (n) anisotropy(r-) and strength coefficient of the material. Also the fractured surfaces after stretching have undergone the some metallurgical investigations and attempt has been made to co-relate with the formability of EDD steel sheets. They are co-related and good agreement with FLDs at various temperatures.

Keywords: FLD, microhardness, strain distribution profile, stretch forming

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Authors: Hassan A. Alshahrani, Mehdi H. Hojjati

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In order to predict and model wrinkling which is caused by out of plane deformation due to compressive loading in the plane of the material during composite prepregs forming, it is necessary to quantitatively understand the relative magnitude of the bending stiffness. This study aims to examine the bending properties of out-of-autoclave (OOA) thermosetting prepreg under vertical cantilever test condition. A direct method for characterizing the bending behavior of composite prepregs was developed. The results from direct measurement were compared with results derived from an image-processing procedure that analyses the captured image during the vertical bending test. A numerical simulation was performed using ABAQUS to confirm the bending stiffness value.

Keywords: Bending stiffness, out-of-autoclave prepreg, forming process, numerical simulation.

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Authors: Jemal Ebrahim Dessie, Lukács Zsolt

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High-strength aluminum alloys have drawn a lot of attention because of the expanding demand for lightweight vehicle design in the automotive sector. Due to poor formability at room temperature, warm and hot forming have been advised. However, warm and hot forming methods need more steps in the production process and an advanced tooling system. In contrast, since ordinary tools can be used, forming sheets at room temperature in the W temper condition is advantageous. However, springback of supersaturated sheets and their thinning are critical challenges and must be resolved during the use of this technique. In this study, AA6082-T6 aluminum alloy was solution heat treated at different oven temperatures and times using a specially designed and developed furnace in order to optimize the W-temper heat treatment temperature. A U-shaped bending test was carried out at different time periods between W-temper heat treatment and forming operation. Finite element analysis (FEA) of U-bending was conducted using AutoForm aiming to validate the experimental result. The uniaxial tensile and unload test was performed in order to determine the kinematic hardening behavior of the material and has been optimized in the Finite element code using systematic process improvement (SPI). In the simulation, the effect of friction coefficient & blank holder force was considered. Springback parameters were evaluated by the geometry adopted from the NUMISHEET ’93 benchmark problem. It is noted that the change of shape was higher at the more extended time periods between W-temper heat treatment and forming operation. Die radius was the most influential parameter at the flange springback. However, the change of shape shows an overall increasing tendency on the sidewall as the increase of radius of the punch than the radius of the die. The springback angles on the flange and sidewall seem to be highly influenced by the coefficient of friction than blank holding force, and the effect becomes increases as increasing the blank holding force.

Keywords: aluminum alloy, FEA, springback, SPI, U-bending, W-temper

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Authors: Dalia Salem, Detlef Schulz

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As Germany pursues its ambitious plan towards a power system based on renewable energy sources, the necessity to establish steady, robust microgrids becomes more evident. Inside the microgrid, there is at least one grid-forming inverter responsible for generating the coupling voltage and stabilizing the system frequency within the standardized accepted limits when the microgrid is forced to operate as a stand-alone power system. Grid-forming control for distributed inverters is required to enable steady control of a low-inertia power system. In this paper, a designed droop control technique is tested at the controller of an inverter as a component of a hardware test bed to understand the microgrid behavior in two modes of operation: i) grid-connected and ii) operating in islanding mode. This droop technique includes many current and voltage inner control loops, where the Q-V and P-f droop provide the required terminal output voltage and frequency. The technique is tested first in a simulation model of the inverter in MATLAB/SIMULINK, and the results are compared to the results of the hardware laboratory test. The results of this experiment illuminate the pivotal role of the grid-forming inverter in facilitating microgrid resilience during grid disconnection events and how microgrids could provide the functionality formerly provided by synchronous machinery, such as the black start process.

Keywords: microgrid, grid-forming inverters, droop-control, islanding-operation

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Authors: Muhammad Kashif Yar, Muhammad Hayat Jaspal, Muawuz Ijaz, Zafar Hayat, Iftikhar Hussain Badar, Jamal Nasir

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Meat quality characteristics such as ultimate pH (pHu), color, cooking loss and shear force of eight wholesale meat cuts of humped cattle (Bos indicus) and water buffalo (Bubalus bubalis) bulls at two age groups were evaluated. A total of 48 animals, 24 of each species and within species 12 from each 18 and 26 months age group were slaughtered. After 24h post-slaughter, eight meat cuts, i.e., tenderloin, sirloin, rump, cube roll, round, topside, silverside and blade were cut from the carcass. The pHu of tenderloin (5.65 vs 5.55), sirloin (5.67 vs 5.60), cube roll (5.68 vs 5.62) and blade (5.88 vs 5.72) was significantly higher (P<0.05) in buffalo than cattle. The tenderloin showed significantly higher (44.63 vs 42.23) and sirloin showed lower (P<0.05) mean L* value (42.28 vs 44.47) in cattle than buffalo whilst the mean L* value of the only tenderloin was affected by animal age. Species had a significant (P<0.05) effect on mean a*, b*, C, and h values of all meat cuts. The shear force of the majority of meat cuts, within species and age groups, varied considerably. The mean shear values of tenderloin, sirloin, cube roll and blade were higher (P<0.05) in buffalo than cattle. The shear values of rump, round, topside and silverside increased significantly (P<0.05) with animal age. In conclusion, primal cuts of cattle showed better meat quality especially tenderness than buffalo. Furthermore, calves should be raised at least up to 26 months of age to maximize profitability by providing better quality meat.

Keywords: buffalo, cattle, meat color, meat quality, slaughtering age, tenderness

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Authors: Noury Bakrim

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When dealing with motivation/arbitrariness, forming form (Forma Formans) and morphodynamics are to be grasped as relevant implications of enunciation/enactment, schematization within the specificity of language as sound/meaning articulation. Thus, the fact that a language is a form does not contradict stasis/dynamic enunciation (reflexivity vs double articulation). Moreover, some languages exemplify the role of the forming form, uttering, and schematization (roots in Semitic languages, the Chinese case). Beyond the evolutionary biosemiotic process (form/substance bifurcation, the split between realization/representation), non-isomorphism/asymmetry between linguistic form/norm and linguistic realization (phonetics for instance) opens up a new horizon problematizing the role of Brain – sensorimotor contribution in the continuous forming form. Therefore, we hypothesize biotization as both process/trace co-constructing motivation/forming form. Henceforth, referring to our findings concerning distribution and motivation patterns within Berber written texts (pulse based obstruents and nasal-lateral levels in poetry) and oral storytelling (consonant intensity clustering in quantitative and semantic/prosodic motivation), we understand consonant clustering, motivation and schematization as a complex phenomenon partaking in patterns of oral/written iconic prosody and reflexive metalinguistic representation opening the stable form. We focus our inquiry on both Amazigh and English clusters (/spl/, /spr/) and iconic consonant iteration in [gnunnuy] (to roll/tumble), [smummuy] (to moan sadly or crankily). For instance, the syllabic structures of /splaeʃ/ and /splaet/ imply an anamorphic representation of the state of the world: splash, impact on aquatic surfaces/splat impact on the ground. The pair has stridency and distribution as distinctive features which specify its phonetic realization (and a part of its meaning) /ʃ/ is [+ strident] and /t/ is [+ distributed] on the vocal tract. Schematization is then a process relating both physiology/code as an arthron vocal/bodily, vocal/practical shaping of the motor-articulatory system, leading to syntactic/semantic thematization (agent/patient roles in /spl/, /sm/ and other clusters or the tense uvular /qq/ at the initial position in Berber). Furthermore, the productivity of serial syllable sequencing in Berber points out different expressivity forms. We postulate two Components of motivated formalization: i) the process of memory paradigmatization relating to sequence modeling under sensorimotor/verbal specific categories (production/perception), ii) the process of phonotactic selection - prosodic unconscious/subconscious distribution by virtue of iconicity. Basing on multiple tests including a questionnaire, phonotactic/visual recognition and oral/written reproduction, we aim at patterning/conceptualizing consonant schematization and motivation among EFL and Amazigh (Berber) learners and speakers integrating biolinguistic hypotheses.

Keywords: consonant motivation and prosody, language and order of life, anamorphic representation, represented representation, biotization, sensori-motor and brain representation, form, formalization and schematization

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Authors: Amir Nazemi, Milad Ramezankhani, Marian Kӧrber, Abbas S. Milani

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The excellent strength to weight ratio of woven fabric composites, along with their high formability, is one of the primary design parameters defining their increased use in modern manufacturing processes, including those in aerospace and automotive. However, for emerging automated preform processes under the smart manufacturing paradigm, complex geometries of finished components continue to bring several challenges to the designers to cope with manufacturing defects on site. Wrinklinge. g. is a common defectoccurring during the forming process and handling of semi-finished textile composites. One of the main reasons for this defect is the weak bending stiffness of fibers in unconsolidated state, causing excessive relative motion between them. Further challenges are represented by the automated handling of large-area fiber blanks with specialized gripper systems. For fabric composites forming simulations, the finite element (FE)method is a longstanding tool usedfor prediction and mitigation of manufacturing defects. Such simulations are predominately meant, not only to predict the onset, growth, and shape of wrinkles but also to determine the best processing condition that can yield optimized positioning of the fibers upon forming (or robot handling in the automated processes case). However, the need for use of small-time steps via explicit FE codes, facing numerical instabilities, as well as large computational time, are among notable drawbacks of the current FEtools, hindering their extensive use as fast and yet efficient digital twins in industry. This paper presents a novel woven fabric simulation technique through the application of the material point method (MPM), which enables the use of much larger time steps, facing less numerical instabilities, hence the ability to run significantly faster and efficient simulationsfor fabric materials handling and forming processes. Therefore, this method has the ability to enhance the development of automated fiber handling and preform processes by calculating the physical interactions with the MPM fiber models and rigid tool components. This enables the designers to virtually develop, test, and optimize their processes based on either algorithmicor Machine Learning applications. As a preliminary case study, forming of a hemispherical plain weave is shown, and the results are compared to theFE simulations, as well as experiments.

Keywords: material point method, woven fabric composites, forming, material handling

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Authors: Surendra Kumar Chourasiya, Sandeep Kumar, Devendra Singh

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In the present investigation tribological behavior of Al-6Si-1Mg-1Graphite composite has been explained. The composite was developed through the unique spray forming route in the spray forming chamber by using N₂ gas at 7kg/cm² and the flight distance was 400 mm. Spray formed composite having a certain amount of porosity which was reduced by the deformations. The composite was subjected to the warm rolling (WR) at 250ºC up to 40% reduction. Spray forming composite shows the considerable microstructure refinement, equiaxed grains, distribution of silicon and graphite particles in the primary matrix of the composite. Graphite (Gr) was incorporated externally during the process that works as a solid lubricant. Porosity decreased after reduction and hardness increases. Pin on disc test has been performed to analyze the wear behavior which is the function of sliding distance for all percent reduction of the composite. 30% WR composite shows the better result of wear rate and coefficient of friction. The improved wear properties of the composite containing Gr are discussed in light of the microstructural features of spray formed the composite and the nature of the debris particles. Scanning electron microscope and optical microscope analysis of the present material supported the prediction of aforementioned changes.

Keywords: Al-6Si-1Mg-1Graphite, spray forming, warm rolling, wear

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Authors: Sankara Rao Gollu, Ramakant Sharma, G. Srinivas, Souvik Kundu, Dipti Gupta

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In recent years, bulk heterojunction organic solar cells (BHJ OSCs) based on polymer–fullerene attracted a large research attention due to their numerous advantages such as light weight, easy processability, eco-friendly, low-cost, and capability for large area roll-to-roll manufacturing. BHJ OSCs usually suffer from insufficient light absorption due to restriction on keeping thin ( < 150 nm) photoactive layer because of small exciton diffusion length ( ~ 10 nm) and low charge carrier mobilities. It is thus highly desirable that light absorption as well as charge transport properties are enhanced by alternative methods so as to improve the device efficiency. In this work, therefore, we have focused on the strategy of incorporating metallic nanostructures in the active layer or charge transport layer to enhance the absorption and improve the charge transport.

Keywords: organic solar cell, efficiency, bulk heterojunction, polymer-fullerene

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Authors: Manwendra Kumar Tripathi, Subhas Ganguly

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A few glass forming ability expressions in terms of characteristic temperatures have been proposed in the literature. Attempts have been made to correlate the expression with the critical diameter of the bulk metallic glass composition. However, with the advent of new alloys, many exceptions have been noted and reported. In the present approach, a genetic programming based code which generates an expression in terms of input variables, i.e., three characteristic temperatures viz. glass transition temperature (Tg), onset crystallization temperature (Tx) and offset temperature of melting (Tl) with maximum correlation with a critical diameter (Dmax). The expression evolved shows improved correlation with the critical diameter. In addition, the expression can be explained on the basis of time-temperature transformation curve.

Keywords: glass forming ability, genetic programming, bulk metallic glass, critical diameter

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Authors: Mohamed Habireche, Nacer E. Bacha, Mohamed Djeghdjough

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In the brick industry, smooth double roll crusher is used for medium and fine crushing of soft to medium hard material. Due to opposite inward rotation of the rolls, the feed material is nipped between the rolls and crushed by compression. They are subject to intense wear, known as three-body abrasion, due to the action of abrasive products. The production downtime affecting productivity stems from two sources: the bi-monthly rectification of the roll crushers and their replacement when they are completely worn out. Choosing the right material for the roll crushers should result in longer machine cycles, and reduced repair and maintenance costs. All roll crushers are imported from outside Algeria. This results in sometimes very long delivery times which handicap the brickyards, in particular in respecting delivery times and honored the orders made by customers. The aim of this work is to investigate the effect of alloying additions on microstructure and wear behavior of grey lamellar cast iron for smooth roll crushers in brick industry. The base gray iron was melted in an induction furnace with low frequency at a temperature of 1500 °C, in which return cast iron scrap, new cast iron ingot, and steel scrap were added to the melt to generate the desired composition. The chemical analysis of the bar samples was carried out using Emission Spectrometer Systems PV 8050 Series (Philips) except for the carbon, for which a carbon/sulphur analyser Elementrac CS-i was used. Unetched microstructure was used to evaluate the graphite flake morphology using the image comparison measurement method. At least five different fields were selected for quantitative estimation of phase constituents. The samples were observed under X100 magnification with a Zeiss Axiover T40 MAT optical microscope equipped with a digital camera. SEM microscope equipped with EDS was used to characterize the phases present in the microstructure. The hardness (750 kg load, 5mm diameter ball) was measured with a Brinell testing machine for both treated and as-solidified condition test pieces. The test bars were used for tensile strength and metallographic evaluations. Mechanical properties were evaluated using tensile specimens made as per ASTM E8 standards. Two specimens were tested for each alloy. From each rod, a test piece was made for the tensile test. The results showed that the quenched and tempered alloys had best wear resistance at 400 °C for alloyed grey cast iron (containing 0.62%Mn, 0.68%Cr, and 1.09% Cu) due to fine carbides in the tempered matrix. In quenched and tempered condition, increasing Cu content in cast irons improved its wear resistance moderately. Combined addition of Cu and Cr increases hardness and wear resistance for a quenched and tempered hypoeutectic grey cast iron.

Keywords: casting, cast iron, microstructure, heat treating

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Authors: Sang-Woo Kim, Young-Seon Lee

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An important concern in metal forming, even at elevated temperatures, is whether a desired deformation can be accomplished without any failure of the material. A detailed understanding of the critical condition for crack initiation provides not only the workability limit of a material but also a guide-line for process design. This paper describes the utilization of ductile fracture criteria in conjunction with the finite element method (FEM) for predicting the onset of fracture in warm metal working processes of magnesium alloy sheets. Critical damage values for various ductile fracture criteria were determined from uniaxial tensile tests and were expressed as the function of strain rate and temperature. In order to find the best criterion for failure prediction, Erichsen cupping tests under isothermal conditions and FE simulations combined with ductile fracture criteria were carried out. Based on the plastic deformation histories obtained from the FE analyses of the Erichsen cupping tests and the critical damage value curves, the initiation time and location of fracture were predicted under a bi-axial tensile condition. The results were compared with experimental results and the best criterion was recommended. In addition, the proposed methodology was used to predict the onset of fracture in non-isothermal deep drawing processes using an irregular shaped blank, and the results were verified experimentally.

Keywords: magnesium, AZ31 alloy, ductile fracture, FEM, sheet forming, Erichsen cupping test

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Authors: Naser Ojaroudi Parchin, Atta Ullah, Haleh Jahanbakhsh Basherlou, Raed A. Abd-Alhameed, Peter S. Excell

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A design of beam-steerable antenna array for the future cellular communication (5G) is presented. The proposed design contains eight elements of compact end-fire antennas arranged on the top edge of smartphone printed circuit board (PCB). Configuration of the antenna element consists of the conductive patterns on the top and bottom copper foil layers and a substrate layer with a via-hole. The simulated results including input-impedance and also fundamental radiation properties have been presented and discussed. The impedance bandwidth (S₁₁ ≤ -10 dB) of the antenna spans from 17.5 to 21 GHz (more than 3 GHz bandwidth) with a resonance at 19 GHz. The antenna exhibits end-fire (directional) radiation beams with wide-angle scanning property and could be used for the future 5G beam-forming. Furthermore, the characteristics of the array design in the vicinity of user-hand are studied.

Keywords: beam-steering, end-fire radiation mode, mobile-phone antenna, phased array

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Authors: Zeradam Yeshiwas, A. Krishnaia

Abstract:

The aim of this study is to verify the resulting surface roughness of parts formed by the Single-Point Incremental Forming (SPIF) process for an ISO 3574 Drawing Quality Cold Rolled CR2 Steel. The chemical composition of drawing quality Cold Rolled CR2 steel is comprised of 0.12 percent of carbon, 0.5 percent of manganese, 0.035 percent of sulfur, 0.04 percent phosphorous, and the remaining percentage is iron with negligible impurities. The experiments were performed on a 3-axis vertical CNC milling machining center equipped with a tool setup comprising a fixture and forming tools specifically designed and fabricated for the process. The CNC milling machine was used to transfer the tool path code generated in Mastercam 2017 environment into three-dimensional motions by the linear incremental progress of the spindle. The blanks of Drawing Quality Cold Rolled CR2 steel sheets of 1 mm of thickness have been fixed along their periphery by a fixture and hardened high-speed steel (HSS) tools with a hemispherical tip of 8, 10 and 12mm of diameter were employed to fabricate sample parts. To investigate the surface roughness, hyperbolic-cone shape specimens were fabricated based on the chosen experimental design. The effect of process parameters on the surface roughness was studied using three important process parameters, i.e., tool diameter, feed rate, and step depth. In this study, the Taylor-Hobson Surtronic 3+ surface roughness tester profilometer was used to determine the surface roughness of the parts fabricated using the arithmetic mean deviation (Rₐ). In this instrument, a small tip is dragged across a surface while its deflection is recorded. Finally, the optimum process parameters and the main factor affecting surface roughness were found using the Taguchi design of the experiment and ANOVA. A Taguchi experiment design with three factors and three levels for each factor, the standard orthogonal array L9 (3³) was selected for the study using the array selection table. The lowest value of surface roughness is significant for surface roughness improvement. For this objective, the ‘‘smaller-the-better’’ equation was used for the calculation of the S/N ratio. The finishing roughness parameter Ra has been measured for the different process combinations. The arithmetic means deviation (Rₐ) was measured via the experimental design for each combination of the control factors by using Taguchi experimental design. Four roughness measurements were taken for a single component and the average roughness was taken to optimize the surface roughness. The lowest value of Rₐ is very important for surface roughness improvement. For this reason, the ‘‘smaller-the-better’’ Equation was used for the calculation of the S/N ratio. Analysis of the effect of each control factor on the surface roughness was performed with a ‘‘S/N response table’’. Optimum surface roughness was obtained at a feed rate of 1500 mm/min, with a tool radius of 12 mm, and with a step depth of 0.5 mm. The ANOVA result shows that step depth is an essential factor affecting surface roughness (91.1 %).

Keywords: incremental forming, SPIF, drawing quality steel, surface roughness, roughness behavior

Procedia PDF Downloads 38

Authors: Sanjay Patil, Shakil A. Kagzi, Harit K. Raval

Abstract:

Tailor Welded Blanks (TWB) are utilized in automotive industries widely because of their advantage of weight and cost reduction and maintaining required strength and structural integrity. TWB consist of two or more sheet having dissimilar or similar material and thickness; welded together to form a single sheet before forming it to desired shape. Forming of the tailor welded blank is affected by ratio of thickness of blanks, ratio of their strength, etc. mainly due to in-homogeneity of material. In the present work the relative effect of these parameters on weld line movement is studied during deep drawing of TWB using FE simulation using HYPERWORKS. The simulation is validated with results from the literature. Simulations were than performed based on Taguchi orthogonal array followed by the ANOVA analysis to determine the significance of these parameters on forming of TWB.

Keywords: ANOVA, deep drawing, Tailor Welded Blank (TWB), weld line movement

Procedia PDF Downloads 284

Authors: Marcelo Costa Cardoso, Luciano Pessanha Moreira

Abstract:

In this work, the plastic behaviour of cold-rolled zinc coated dual-phase steel sheets DP600 and DP800 grades is firstly investigated with the help of uniaxial, hydraulic bulge and Forming Limit Curve (FLC) tests. The uniaxial tensile tests were performed in three angular orientations with respect to the rolling direction to evaluate the strain-hardening and plastic anisotropy. True stress-strain curves at large strains were determined from hydraulic bulge testing and fitted to a work-hardening equation. The limit strains are defined at both localized necking and fracture conditions according to Nakajima’s hemispherical punch procedure. Also, an elasto-plastic localization model is proposed in order to predict strain and stress based forming limit curves. The investigated dual-phase sheets showed a good formability in the biaxial stretching and drawing FLC regions. For both DP600 and DP800 sheets, the corresponding numerical predictions overestimated and underestimated the experimental limit strains in the biaxial stretching and drawing FLC regions, respectively. This can be attributed to the restricted failure necking condition adopted in the numerical model, which is not suitable to describe the tensile and shear fracture mechanisms in advanced high strength steels under equibiaxial and biaxial stretching conditions.

Keywords: advanced high strength steels, forming limit curve, numerical modelling, sheet metal forming

Procedia PDF Downloads 345

Authors: Rasim Alguliev, Farhad Yusifov

Abstract:

Considering the international experience, conceptual and architectural principles of forming of electron government are researched and some suggestions were made. The assessment of monitoring of forming processes of electron government, intellectual analysis of web-resources, provision of information security, electron democracy problems were researched, conceptual approaches were suggested. By taking into consideration main principles of electron government theory, important research directions were specified.

Keywords: electron government, public administration, information security, web-analytics, social networks, data mining

Procedia PDF Downloads 437

Authors: Jawad Zakir, Syed Irtiza Ali Shah, Rana Shaharyar, Sidra Mahmood

Abstract:

Y-force equation comprises aerodynamic forces, drag and side force with side slip angle β and weight component along with the coupled roll (φ) and pitch angles (θ). This research deals with the linearization of Y-force equation using Small Disturbance theory assuming equilibrium flight conditions for different state variables of aircraft. By using assumptions of Small Disturbance theory in non-linear Y-force equation, finally reached at linearized lateral rigid body equation of motion; which says that in linearized Y-force equation, the lateral acceleration is dependent on the other different aerodynamic and propulsive forces like vertical tail, change in roll rate (Δp) from equilibrium, change in yaw rate (Δr) from equilibrium, change in lateral velocity due to side force, drag and side force components due to side slip, and the lateral equation from coupled rotating frame to decoupled rotating frame. This paper describes implementation of this lateral linearized equation for aircraft control systems. Another significant parameter considered on which y-force equation depends is ‘c’ which shows that any change bought in the weight of aircrafts wing will cause Δφ and cause lateral force i.e. Y_c. This simplification also leads to lateral static and dynamic stability. The linearization of equations is required because much of mathematics control system design for aircraft is based on linear equations. This technique is simple and eases the linearization of the rigid body equations of motion without using any high-speed computers.

Keywords: Y-force linearization, small disturbance theory, side slip, aerodynamic force drag, lateral rigid body equation of motion

Procedia PDF Downloads 459

Authors: Gulijianati Abake, Ryutaro Tateishi

Abstract:

Snow is one kind of special underlying surface, has high reflectivity, low thermal conductivity, and snow broth hydrological effect. Every year, frequent snow disaster in Xinjiang causing considerable economic loss and serious damage to towns and farms, such as livestock casualties, traffic jams and other disaster, therefore monitoring SWE (snow volume) in Xinjiang has a great significance. The problems of how this disaster distributes and what disaster-forming environments are important to its occurrence are the most pressing problems in disaster risk assessment and salvage material arrangement. The present study aims 1) to monitor accurate SWE using MODIS, AMSRE, and CMC data, 2) to establish the regularity of snow disaster outbreaks and the important disaster-forming environmental factors. And a spatial autocorrelation analysis method and a canonical correlation analysis method are used to answer these two questions separately, 3) to prepare the way to salvage material arrangements for snow disasters.

Keywords: snow water equivalent (snow volume), AMSR-E, CMC snow depth, snow disaster

Procedia PDF Downloads 349