Search results for: roller burnishing

Authors: Tobias Beyer, Christoph Friedrich

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Modern simulation methodology using finite element models is nowadays a recognized tool for product design/optimization. Likewise, manufacturing process design is increasingly becoming the focus of simulation methodology in order to enable sustainable results based on reduced real-life tests here as well. In this article, two process simulations -radial riveting and roller burnishing- used for mechanical joining of components are explained. In the first step, the required boundary conditions are developed and implemented in the respective simulation models. This is followed by process space validation. With the help of the validated models, the interdependencies of the input parameters are investigated and evaluated by means of sensitivity analyses. Limit case investigations are carried out and evaluated with the aid of the process simulations. Likewise, a comparison of the two joining methods to each other becomes possible.

Keywords: FEM, model-based process development, process simulation, radial riveting, roller burnishing, sensitivity analysis

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Authors: Mohammed T. Hayajneh, Adel Mahmood Hassan, Moath AL-Qudah

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Burnishing is increasingly used as a finishing operation to improve surface roughness and surface hardness. This can be achieved by applying a hard ball or roller onto metallic surfaces under pressure, in order to achieve many advantages in the metallic surface. In the present work, the feed rate, speed and force have been considered as the basic burnishing parameters to study the surface roughness and surface hardness of metallic matrix composites. The considered metal matrix composites were made from Aluminum-Magnesium-Graphite with five different weight percentage of graphite. Both effects of burnishing parameters mentioned above and the graphite percentage on the surface hardness and surface roughness of the metallic matrix composites were studied. The results of this investigation showed that the surface hardness of the metallic composites increases with the increase of the burnishing force and decreases with the increase in the burnishing feed rate and burnishing speed. The surface roughness of the metallic composites decreases with the increasing of the burnishing force, feed rate, and speed to certain values, then it starts to increase. On the other hand, the increase in the weight percentage of the graphite in the considered composites causes a decrease in the surface hardness and an increase in the surface roughness.

Keywords: burnishing process, Al-Mg-Graphite composites, surface hardness, surface roughness

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Authors: Litim Tarek, Taamallah Ouahiba

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This work relates to the physico-geometrical aspect of the surface layers of 16NC6 steel having undergone the burnishing treatment by hard steel ball. The results show that the optimal effects of burnishing are closely linked to the shape and the material of the active part of the device as well as to the surface plastic deformation ability of the material to be treated. Thus the roughness is improved by more than 70%, and the consolidation rate is increased by 30%. In addition, modeling of the rational traction curves provides a work hardening coefficient of up to 0.3 in the presence of burnishing.

Keywords: 16NC6 steel, burnishing, hardening, roughness

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Authors: Ouahiba Taamallah, Tarek Litim

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This work relates to the physico-geometrical aspect of the surface layers of 100C6 steel having undergone the burnishing treatment by hard steel ball. The application of tip diamond burnishing promotes better roughness compared to turning. In addition, it allows the surface layers to be consolidated by work hardening phenomena. The optimal effects are closely related to the parameters of the treatment and the active part of the device. With an 80% improvement in roughness resulting from the treatment, burnishing can be defined as a finishing operation within the machining range. With a 40% gain in consolidation rate, this treatment is an efficient process for material consolidation.

Keywords: 100C6 steel, burnishing, hardening, roughness

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Authors: Zs. Kovács, Zs. J. Viharos, J. Kodácsy

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As a well-known conventional finishing process, the grinding is commonly used to manufacture seal mating surfaces and bearing surfaces, but is also creates twisted surfaces. The machined surfaces by turning or grinding usually have twist structure on the surfaces, which can convey lubricants such as conveyor screw. To avoid this phenomenon, have to use special techniques or machines, for example start-stop turning, tangential turning, ultrasonic protection or special toll geometries. All of these solutions have high cost and difficult usability. In this paper, we describe a system and summarize the results of the experimental research carried out mainly in the field of Magnetic Abrasive Polishing (MAP) and Magnetic Roller Burnishing (MRB). These technologies are simple and also green while able to produce twist-free surfaces. During the tests, C45 normalized steel was used as workpiece material which was machined by simple and Wiper geometrical turning inserts in a CNC turning lathe. After the turning, the MAP and MRB technologies can be used directly to reduce the twist of surfaces. The evaluation was completed by advanced measuring and IT equipment.

Keywords: magnetism, finishing, polishing, roller burnishing, twist-free

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Authors: Adrian Travieso Disotuar, J. Antonio Travieso Rodriguez, Ramon Jerez Mesa, Montserrat Vilaseca

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The effect of the non-vibration-assisted and vibration-assisted ball burnishing on both the surface and mechanical properties of C300 obtained by Selective Laser Melting additive manufacturing technology is studied in this paper. Different vibration amplitudes preloads, and burnishing strategies were tested. A topographical analysis was performed to determine the surface roughness of the different conditions. Besides, micro tensile tests were carried out in situ on Scanning Electron Microscopy to elucidate the post-treatment effects on damaging mechanisms. Experiments show that vibration-assisted ball burnishing significantly enhances mechanical properties compared to the non-vibration-assisted method. Moreover, it was found that the surface roughness was significantly improved with respect to the reference surface.

Keywords: additive manufacturing, ball burnishing, mechanical properties, metals, surface roughness

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Authors: Tarek Litim, Ouahiba Taamallah

Abstract:

The present paper is an investigation of the effect of burnishing on the surface integrity of a component made of 15NiCr6 steel. This work shows a statistical study based on regression, and Taguchi's design has allowed the development of mathematical models to predict the output responses as a function of the technological parameters studied. The response surface methodology (RSM) showed a simultaneous influence of the burnishing parameters and observe the optimal processing parameters. ANOVA analysis of the results resulted in the validation of the prediction model with a determination coefficient R=90.60% and 92.41% for roughness and hardness, respectively. Furthermore, a multi-objective optimization allowed to identify a regime characterized by P=10kgf, i=3passes, and f=0.074mm/rev, which favours minimum roughness and maximum hardness. The result was validated by the desirability of D= (0.99 and 0.95) for roughness and hardness, respectively.

Keywords: 15NiCr6 steel, burnishing, surface integrity, Taguchi, RSM, ANOVA

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Authors: Mahesh Chudasama, Harit Raval

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Conical sections and shells of metal plates manufactured by 3-roller conical bending process are widely used in the industries. The process is completed by first bending the metal plates statically and then dynamic roller bending sequentially. It is required to have an analytical model to get maximum bending force, for optimum design of the machine, for static bending stage. Analytical models assuming various stress conditions are considered and these analytical models are compared considering various parameters and reported in this paper. It is concluded from the study that for higher bottom roller inclination, the shear stress affects greatly to the static bending force whereas for lower bottom roller inclination it can be neglected.

Keywords: roller-bending, static-bending, stress-conditions, analytical-modeling

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Authors: Ouahiba Taamallah, Tarek Litim

Abstract:

The study deals with the burnishing effect of AISI 52100 steel and parameters influence (Py, i and f on surface integrity. The results show that the optimal effects are closely related to the treatment parameters. With a 92% improvement in roughness, SB can be defined as a finishing operation within the machining range. Due to 85% gain in consolidation rate, this treatment constitutes an efficient process for work-hardening of material. In addition, a statistical study based on regression and Taguchi's design has made it possible to develop mathematical models to predict output responses according to the studied burnishing parameters. Response Surface Methodology RSM showed a simultaneous influence of the burnishing parameters and to observe the optimal parameters of the treatment. ANOVA Analysis of results led to validate the prediction model with a determination coefficient R2=94.60% and R2=93.41% for surface roughness and micro-hardness, respectively. Furthermore, a multi-objective optimization allowed to identify a regime characterized by P=20 Kgf, i=5 passes and f=0.08 mm.rev-1, which favors minimum surface roughness and a maximum of micro-hardness. The result was validated by a composite desirability D_i=1 for both surface roughness and microhardness, respectively. Applying optimal parameters, burnishing showed its beneficial effects in fatigue resistance, especially for imposed loading in the low cycle fatigue of the material where the lifespan increased by 90%.

Keywords: AISI 52100 steel, burnishing, Taguchi, fatigue

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Authors: Tarek Litim, Ouahiba Taamallah

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Burnishing is a mechanical surface treatment that combines several beneficial effects on the two steel grades studied. The application of burnishing to the ball or to the tip favors a better roughness compared to turning. In addition, it allows the consolidation of the surface layers through work hardening phenomena. The optimal effects are closely related to the treatment parameters and the active part of the device. With an improvement of 78% on the roughness, burnishing can be defined as a finishing operation in the machining range. With a 44% gain in consolidation rate, this treatment is an effective process for material consolidation. These effects are affected by several factors. The factors V, f, P, r, and i have the most significant effects on both roughness and hardness. Ball or tip burnishing leads to the consolidation of the surface layers of both grades 100C6 and 16NC6 steels by work hardening. For each steel grade and its mechanical treatment, the rational tensile curve has been drawn. Lüdwick's law is used to better plot the work hardening curve. For both grades, a material hardening law is established. For 100C6 steel, these results show a work hardening coefficient and a consolidation rate of 0.513 and 44, respectively, compared to the surface layers processed by turning. When 16NC6 steel is processed, the work hardening coefficient is about 0.29. Hardness tests characterize well the burnished depth. The layer affected by work hardening can reach up to 0.4 mm. Simulation of the tests is of great importance to provide the details at the local scale of the material. Conventional tensile curves provide a satisfactory indication of the toughness of 100C6 and 16NC6 materials. A simulation of the tensile curves revealed good agreement between the experimental and simulation results for both steels.

Keywords: 100C6 steel, 16NC6 steel, burnishing, work hardening, roughness, hardness

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Authors: V. Yu. Shungin, A. V. Popov

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At present, one of the main tasks of Russian shipbuilding yards is implementation of new technologies and replacement of main process equipment. In particular, conventional bending technologies with dies are being replaced with resource-saving methods of rotation (roller) banding. Such rolling bending is performed by multiple rolling of a plat in special bending rollers. Studies, conducted in JSC SSTC, allowed developing a theory of rotation bending, methods for calculation of process parameters, requirements to roller presses and bending accessories. This technology allows replacing old and expensive presses with new cheaper roller ones, having less power consumption and bending force. At first, roller presses were implemented in ship repair, however now they are widely employed at major shipbuilding yards. JSC SSTC develops bending technology and carries out design, manufacturing and delivery of roller presses.

Keywords: bending/straightening machines, rotational bending, ship hull structures, multifunctional bending

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Authors: Azadeh Askarinejad, Parmida Hayati, Parham Hayati, Reza Parchami

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Curing is a very important factor in the ultimate strength and durability of roller compacted concrete pavements (RCCP). Curing involves keeping the concrete is saturated or close to saturation point. Since maintaining concrete moisture has a significant impact on its mechanical properties, permeability and durability, curing is important. The most common procedure for curing of roller compacted concrete is using a white pigmented curing compound. This method is effective, economical and fast. In the present study, different curing compounds were applied on concrete specimens and the results of their effects on the mechanical properties were compared with each other and usual methods of curing in order to select appropriate materials and methods of curing for RCCP construction.

Keywords: curing compounds, roller compacted concrete pavements, mechanical properties, durability

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Authors: W. G. Kim, C. H. Jo

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We analyzed the effects of variations in the diameter of silicone rubber and polyvinyl chloride (PVC) tubings on the likelihood of tubing rupture during modeling of accidental arterial line clamping in cardiopulmonary bypass with a roller pump. A closed CPB circuit constructed with a roller pump was tested with both PVC and silicone rubber tubings of 1/2, 3/8, and 1/4 inch internal diameter. Arterial line pressure was monitored, and an occlusive clamp was placed across the tubing distal to the pressure monitor site to model an accidental arterial line occlusion. A CCD camera with 512(H) x 492(V) pixels was installed above the roller pump to measure tubing diameters at pump outlet, where the maximum deformations (distension) of the tubings occurred. Quantitative measurement of the changes of tubing diameters with the change of arterial line pressure was performed using computerized image processing techniques. A visible change of tubing diameter was generally noticeable by around 250 psi of arterial line pressure, which was already very high. By 1500 psi, the PVC tubings showed an increase of diameter of between 5-10 %, while the silicone rubber tubings showed an increase between 20-25 %. Silicone rubber tubings of all sizes showed greater distensibility than PVC tubings of equivalent size. In conclusion, although roller-pump induced tubing rupture remains a theoretical problem during cardiopulmonary bypass in terms of the inherent mechanism of the pump, in reality such an occurrence is impossible in real clinical conditions.

Keywords: roller pump, tubing rupture, cardiopulmonary bypass, arterial line

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Authors: Amine Hamdi, Sidi Mohammed Merghache, Brahim Fernini

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During abrasive machining of hard steels by belt grinding, the finished surface texture is influenced by the pressure between the abrasive belt and the workpiece; this pressure is the force applied by the contact roller on the workpiece. Therefore, the contact roller has an important role and has a direct impact on process efficiency. The objective of this article is to study and compare the influence of different contact rollers on the belt ground surface texture. The quality of the surface texture is characterized by eight roughness parameters (Ra, Rz, Rp, Rv, Rsk, Rku, Rsm, and Rdq) and five parameters of the bearing area curve (Rpk, Rk, Rvk, Mr1, and Mr2). The results of the experimental tests indicate a better surface texture obtained by the PA 6 polyamide roller (hardness 60 Shore D) compared to that obtained with other rollers of the same hardness or of different hardness. Simultaneously, optimum medium pressure between the belt and the workpiece allows chip removal without fracturing the abrasive grains. This generates a good surface texture.

Keywords: belt grinding, contact roller, pressure, abrasive belt, surface texture

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Authors: Paolo Ragazzi, Olivier Peillon, Paul Fauris, Mathias Simon, Raul Navarro, Juan Carlos Martin, Oriol Casasayas, Laura Pacheco, Albert Perez-Bellmunt

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Introduction: The use of stretching techniques in the sports world is frequent and widely used for its many effects. One of the main benefits is the gain in flexibility, range of motion and facilitation of the sporting performance. Recently the use of Roller-Foam (RF) has spread in sports practice both at elite and recreational level for its benefits being similar to those observed in stretching. The objective of the following study is to compare the results of the Roller-Foam with the proprioceptive neuromuscular facilitation stretching (PNF) (one of the stretchings with more evidence) on the hamstring muscles. Study design: The design of the study is a single-blind, randomized controlled trial and the participants are 40 healthy volunteers. Intervention: The subjects are distributed randomly in one of the following groups; stretching (PNF) intervention group: 4 repetitions of PNF stretching (5seconds of contraction, 5 second of relaxation, 20 second stretch), Roller-Foam intervention group: 2 minutes of Roller-Foam was realized on the hamstring muscles. Main outcome measures: hamstring muscles flexibility was assessed at the beginning, during (30’’ of intervention) and the end of the session by using the Modified Sit and Reach test (MSR). Results: The baseline results data given in both groups are comparable to each other. The PNF group obtained an increase in flexibility of 3,1 cm at 30 seconds (first series) and of 5,1 cm at 2 minutes (the last of all series). The RF group obtained a 0,6 cm difference at 30 seconds and 2,4 cm after 2 minutes of application of roller foam. The results were statistically significant when comparing intragroups but not intergroups. Conclusions: Despite the fact that the use of roller foam is spreading in the sports and rehabilitation field, the results of the present study suggest that the gain of flexibility on the hamstrings is greater if PNF type stretches are used instead of RF. These results may be due to the fact that the use of roller foam intervened more in the fascial tissue, while the stretches intervene more in the myotendinous unit. Future studies are needed, increasing the sample number and diversifying the types of stretching.

Keywords: hamstring muscle, stretching, neuromuscular facilitation stretching, roller foam

Procedia PDF Downloads 163

Authors: Chamroeun Chhorn, Seong Jae Hong, Yoon-Ho Cho, Hyun Jong Lee, Seung Woo Lee

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The use of Roller-Compacted Concrete Pavement (RCCP) in public and private applications has been increasing steadily in the past few decades due to its cost saving. This eco-concrete pavement shares construction characteristics from asphalt pavement and material characteristics from the conventional concrete pavement. Due to its low binder and water content, the consistency of Roller-Compacted Concrete (RCC) is typically very stiff. Thus, it is crucial to control the consistency of this concrete. Without appropriate consistency, required density may not be achieved in actual construction for RCCP. The purpose of this study is to investigate the effect on Poly Naphtalene Sulfonate (PNS) superplasticizer on the consistency of RCC as well as its compactibility in actual construction. From this study, it was found that PNS superplasticizer can effectively reduce the stiffness of an RCC mixture and maintain it for a sufficient amount of time without compromising its strength properties. Moreover, it was observed from field test specimens that the use of this admixture can also improve the compaction efficiency throughout the whole depth of pavement.

Keywords: roller-compacted concrete, consistency, compactibility, poly naphthalene sulfonate superplasticizer

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Authors: Yujeong Shin, Seong Jin Cho, Jin Ho Kim

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In the textile-weaving machine, the reed is the core component to separate thousands of strands of yarn and to produce the fabric in a continuous high-speed movement. In addition, the reed affects the quality of the fiber. Therefore, the wire forming analysis of the main raw materials of the reed needs to be considered. Roll-forming is a key technology among the manufacturing process of reed wire using textile machine. A simulation of roll-forming line in accordance with the reduction rate is performed using LS-DYNA. The upper roller, fixed roller and reed wire are modeled by finite element. The roller is set to be rigid body and the wire of SUS430 is set to be flexible body. We predict the variation of the cross-sectional shape of the wire depending on the reduction ratio.

Keywords: textile machine, reed, rolling, reduction ratio, wire

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Authors: O. Zarrin, M. Ramezan Shirazi

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The quality of concrete is usually defined by compressive strength, but flexural strength is the most important characteristic of concrete in a pavement which control the mix design of concrete instead of compressive strength. Therefore, the aggregates which are selected for the pavements are affected by higher flexural strength. Roller Compacting Concrete Pavement (RCCP) is not a new construction method. The other characteristic of this method is no bleeding and less shrinkage due to the lower amount of water. For this purpose, a roller is needed for placing and compacting. The surface of RCCP is not smooth; therefore, the most common use of this pavement is in an industrial zone with slower traffic speed which requires durable and tough pavement. For preparing a smoother surface, it can be achieved by asphalt paver. RCCP decrease the finishing cost because there are no bars, formwork, and the lesser labor need for placing the concrete. In this paper, different aspect of RCCP such as mix design, flexural, compressive strength and focus on the different part of RCCP on detail have been investigated.

Keywords: flexural strength, compressive strength, pavement, asphalt

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Authors: Ravi Raj, Louis Chiu, Deepak Marla, Aijun Huang

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Hybridization of the directed laser deposition (DLD) process using an in-situ micro-roller to impart a vertical compressive load on the deposited bead at elevated temperatures can relieve tensile residual stresses incurred in the process. To investigate this stress relief mechanism and its relationship with the in-situ rolling parameters, a fully coupled dynamic thermo-mechanical model is presented in this study. A single bead deposition of Ti-6Al-4V alloy with an in-situ roller made of mild steel moving at a constant speed with a fixed nominal bead reduction is simulated using the explicit solver of the finite element software, Abaqus. The thermal model includes laser heating during the deposition process and the heat transfer between the roller and the deposited bead. The laser heating is modeled using a moving heat source with a Gaussian distribution, applied along the pre-formed bead’s surface using the VDFLUX Fortran subroutine. The bead’s cross-section is assumed to be semi-elliptical. The interfacial heat transfer between the roller and the bead is considered in the model. Besides, the roller is cooled internally using axial water flow, considered in the model using convective heat transfer. The mechanical model for the bead and substrate includes the effects of rolling along with the deposition process, and their elastoplastic material behavior is captured using the J2 plasticity theory. The model accounts for strain, strain rate, and temperature effects on the yield stress based on Johnson-Cook’s theory. Various aspects of this material behavior are captured in the FE software using the subroutines -VUMAT for elastoplastic behavior, VUHARD for yield stress, and VUEXPAN for thermal strain. The roller is assumed to be elastic and does not undergo any plastic deformation. Also, contact friction at the roller-bead interface is considered in the model. Based on the thermal results of the bead, the distance between the roller and the deposition nozzle (roller o set) can be determined to ensure rolling occurs around the beta-transus temperature for the Ti-6Al-4V alloy. It is identified that roller offset and the nominal bead height reduction are crucial parameters that influence the residual stresses in the hybrid process. The results obtained from a simulation at roller offset of 20 mm and nominal bead height reduction of 7% reveal that the tensile residual stresses decrease to about 52% due to in-situ rolling throughout the deposited bead. This model can be used to optimize the rolling parameters to minimize the residual stresses in the hybrid DLD process with in-situ micro-rolling.

Keywords: directed laser deposition, finite element analysis, hybrid in-situ rolling, thermo-mechanical model

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Authors: Adam L. Yanagihara, Yong Seok Park

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The goal of this paper is to converge upon a design of a brake system that could be used for a roller coaster found at an amusement park. It was necessary to find what could be deemed as a “comfortable” deceleration so that passengers do not feel as if they are suddenly jerked and pressed against the restraining harnesses. A human factors engineering approach was taken in order to determine this deceleration. Using a previous study that tested the deceleration of transit vehicles, it was found that a -0.45 G deceleration would be used as a design requirement to build this system around. An adjustable linear eddy current brake using permanent magnets would be the ideal system to use in order to meet this design requirement. Anthropometric data were then used to determine a realistic weight and length of the roller coaster that the brake was being designed for. The weight and length data were then factored into magnetic brake force equations. These equations were used to determine how the brake system and the brake run layout would be designed. A final design for the brake was determined and it was found that a total of 12 brakes would be needed with a maximum braking distance of 53.6 m in order to stop a roller coaster travelling at its top speed and loaded to maximum capacity. This design is derived from theoretical calculations, but is within the realm of feasibility.

Keywords: eddy current brake, engineering design, design synthesis, human factors engineering

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Authors: Pramod Keshav Kolase, Atul K. Desai

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This paper presents the experimental investigation results of Ultrasonic Pulse Velocity (UPV) tests conducted on roller compacted concrete pavement (RCCP) material containing Class F fly ash of as mineral admixture and triangular polyester fiber as a secondary reinforcement. The each mix design series fly ash content is varied from 0% to 45 % and triangular polyester fiber 0% to 0.75% by volume fraction. In each series and for different ages of curing (i.e. 7, 28 and 90 days) forty-eight cube specimens are cast and tested for compressive strength and UPV. The UPV of fly ash was found to be lower for all mixtures at 7 days in comparison with control mix concrete. But at 28, 56 days and 90 days the UPV were significantly improved for all the mixes. Relationships between compressive strength of RCCP and UPV and Dynamic Elastic Modulus are proposed for all series mixes.

Keywords: compressive strength, dynamic elastic modulus, fly ash, fiber, roller compacted concrete, ultrasonic pulse velocity

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Authors: Han Kexi, Lv Xuewei, Song Bing

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This paper focuses on the preparation of pelletizing with the Panzhihua ilmenite concentrate to satisfy the requirement of smelting titania slag. The effects of the moisture content, mixing time of raw materials, pressure of pellet, roller rotating speed of roller, drying temperature and time on the pelletizing yield and compressive strength were investigated. The experimental results show that the moister content was controlled at 2.0%~2.5%, mixing time at 20 min, the pressure of the ball forming machine at 13~15 mpa, the pelletizing yield can reach up 85%. When the roller rotating speed is 6~8 r/min while the drying temperature and time respectively is 350 ℃ and 40~60 min, the compressive strength of pelletizing more than 1500 N. The preparation of pelletizing can meet the requirement of smelting titania slag.

Keywords: Panzhihua fine ilmenite concentrate, pelletizing, pelletizing yield, compressive strength, drying

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Authors: C. Chhorn, S. H. Han, S. W. Lee

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Roller-compacted concrete (RCC) has been used for decades in many pavement applications due to its economic cost and high construction speed. However, due to the lack of deep researches and experiences, this material has not been widely employed. An RCC mixture with appropriate consistency can induce high compacted density, while high density can induce good aggregate interlock and high strength. Consistency of RCC is mainly known to define its constructability. However, it was not well specified how this property may affect other properties of a constructed RCC pavement (RCCP). This study suggested the possibility of an ideal range of consistency that may provide adequate quality of RCCP. In this research, five sections of RCCP consisted of both 13 mm and 19 mm aggregate sections were investigated. The effects of consistency on compacted depth, strength, international roughness index (IRI), skid resistance are examined. From this study, a new range of consistency is suggested for RCCP application.

Keywords: compacted depth, consistency, international roughness index (IRI), pavement, roller-compacted concrete (RCC), skid resistance, strength

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Authors: Omid Pourabdollah, Mohsen Misaghian

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Overtopping is known as one the most important reasons for the failure of earth dams. In some cases, it has resulted in heavy damages and losses. Therefore, enhancing the safety of earth dams against overtopping has received much attention in the past four decades. In this paper, at first, the overtopping phenomena and its destructive consequences will be introduced. Then, overtopping failure mechanism of embankments will be described. Finally, different types of protection systems for stabilization of earth dams against overtopping will be presented. These include timber cribs, riprap and gabions, reinforced earth, roller compacted concrete, and the precast concrete blocks.

Keywords: embankment dam, overtopping, roller compacted concrete, wedge concrete block

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Authors: Amol M. Jadhav, Sharad S. Chudhari, S. S. Khedkar

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This review presents a through survey of research paper work on the experimental analysis, FEM Analysis & simulation of the metal spinning process. In this literature survey all the papers being taken from Elsevier publication and most of the from journal of material processing technology. In a last two decade or so, metal spinning process gradually used as chip less formation for the production of engineering component in a small to medium batch quantities. The review aims to provide include into the experimentation, FEM analysis of various components, simulation of metal spinning process and act as guide for research working on metal spinning processes. The review of existing work has several gaps in current knowledge of metal spinning processes. The evaluation of experiment is thickness strain, the spinning force, the twisting angle, the surface roughness of the conventional & shear metal spinning process; the evaluation of FEM of metal spinning to path definition with sufficient fine mesh to capture behavior of work piece; The evaluation of feed rate of roller, direction of roller,& type of roller stimulated. The metal spinning process has the more flexible to produce a wider range of product shape & to form more challenge material.

Keywords: metal spinning, FEM analysis, simulation of metal spinning, mechanical engineering

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Authors: Jae-Yong Lee, Gyu-Hyun Bae, Yun-Soo Chung, Dae-Sub Kim, Jae-Sung Bae

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In general, fabric is heat-treated using a stenter machine in order to dry and fix its shape. It is important to shape before the heat treatment because it is difficult to revert back once the fabric is formed. To produce the product of right shape, camera type weft straightener has been applied recently to capture and process fabric images quickly. It is more powerful in determining the final textile quality rather than photo-sensor. Positioning in front of a stenter machine, weft straightener helps to spread fabric evenly and control the angle between warp and weft constantly as right angle by handling skew and bow rollers. To process this tricky procedure, the structural analysis should be carried out in advance, based on which, its control technology can be drawn. A structural analysis is to figure out the specific contact/slippage characteristics between fabric and roller. We already examined the applicability of camera type weft straightener to plain weave fabric and found its possibility and the specific working condition of machine and rollers. In this research, we aimed to explore another applicability of camera type weft straightener. Namely, we tried to figure out camera type weft straightener can be used for fabrics. To find out the optimum condition, we increased the number of rollers. The analysis is done by ANSYS software using Finite Element Analysis method. The control function is demonstrated by experiment. In conclusion, the structural analysis of weft straightener is done to identify a specific characteristic between roller and fabrics. The control of skew and bow roller is done to decrease the error of the angle between warp and weft. Finally, it is proved that camera type straightener can also be used for the special fabrics.

Keywords: camera type weft straightener, structure analysis, control, skew and bow roller

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Authors: Jun Hee Lee, Young Kyu Kim, Seong Jae Hong, Chamroeun Chhorn, Seung Woo Lee

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Roller-compacted concrete pavement (RCCP), an environmental friendly pavement of which load carry capacity benefitted from both hydration and aggregate interlock from roller compacting, demonstrated a superb structural performance for a relatively small amount of water and cement content. Even though an excellent structural performance can be secured, it is required to investigate roller-compacted concrete (RCC) under environmental loading and its long-term durability under critical conditions. In order to secure long-term durability, an appropriate internal air-void structure is required for this concrete. In this study, a method for improving the long-term durability of RCCP is suggested by analyzing the internal air-void structure and corresponding durability of RCC. The method of improving the long-term durability involves measurements of air content, air voids, and air-spacing factors in RCC that experiences changes in terms of type of air-entraining agent and its usage amount. This test is conducted according to the testing criteria in ASTM C 457, 672, and KS F 2456. It was found that the freezing-thawing and scaling resistances of RCC without any chemical admixture was quite low. Interestingly, an improvement of freezing-thawing and scaling resistances was observed for RCC with appropriate the air entraining (AE) agent content; Relative dynamic elastic modulus was found to be more than 80% for those mixtures. In RCC with AE agent mixtures, large amount of air was distributed within a range of 2% to 3%, and an air void spacing factor ranging between 200 and 300 μm (close to 250 μm, recommended by PCA) was secured. The long-term durability of RCC has a direct relationship with air-void spacing factor, and thus it can only be secured by ensuring the air void spacing factor through the inclusion of the AE in the mixture.

Keywords: durability, RCCP, air spacing factor, surface scaling resistance test, freezing and thawing resistance test

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Authors: Mahesh K. Chudasama, Harit K. Raval

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3-roller conical bending process is widely used in the industries for manufacturing of conical sections and shells. It involves static as well dynamic bending stages. Analytical models for prediction of bending force during static as well as dynamic bending stage are available in the literature. In this paper, bending forces required for static bending stage and dynamic bending stages have been compared using the analytical models. It is concluded that force required for dynamic bending is very less as compared to the bending force required during the static bending stage.

Keywords: analytical modeling, cone frustum, dynamic bending, static bending

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Authors: Orod Zarrin, Mohsen Ramezan Shirazi

Abstract:

Rehabilitation of dam components such as foundations, buttresses, spillways and overtopping protection require a wide range of construction and design methodologies. Geotechnical Engineering considerations play an important role in the design and construction of foundations of new dams. Much investigation is required to assess and evaluate the existing dams. The application of roller compacting concrete (RCC) has been accepted as a new method for constructing new dams or rehabilitating old ones. In the past 40 years there have been so many changes in the usage of RCC and now it is one of most satisfactory solutions of water and hydropower resource throughout the world. The considerations of rehabilitation and construction of dams might differ due to upstream reservoir and its influence on penetrating and dewatering of downstream, operations requirements and plant layout. One of the advantages of RCC is its rapid placement which allows the dam to be operated quickly. Unlike ordinary concrete it is a drier mix, and stiffs enough for compacting by vibratory rollers. This paper evaluates some different aspects of RCC and focuses on its preparation progress.

Keywords: spillway, vibrating consistency, fly ash, water tightness, foundation

Procedia PDF Downloads 571

Authors: Sagar Ghos, Andrew E. Elaryan, Syed Ashik Ali, Musharraf Zaman, Mohammed Ashiqur Rahman

Abstract:

Achieving desired density during construction is an important indicator of pavement quality. Insufficient compaction often compromises pavement performance and service life. Intelligent compaction (IC) is an emerging technology for monitoring compaction quality during the construction of asphalt pavements. This paper aims to provide an overview of findings from four case studies in Oklahoma involving the compaction quality of asphalt pavements, namely SE 44th St project (Project 1) and EOC Turnpike project (Project 2), Highway 92 project (Project 3), and 108th Avenue project (Project 4). For this purpose, an IC technology, the intelligent compaction analyzer (ICA), developed at the University of Oklahoma, was used to evaluate compaction quality. Collected data include GPS locations, roller vibrations, roller speed, the direction of movement, and temperature of the asphalt mat. The collected data were analyzed using a widely used software, VETA. The average densities for Projects 1, 2, 3 and 4, were found as 89.8%, 91.50%, 90.7% and 87.5%, respectively. The maximum densities were found as 94.6%, 95.8%, 95.9%, and 89.7% for Projects 1, 2, 3, and 4, respectively. It was observed that the ICA estimated densities correlated well with the field core densities. The ICA results indicated that at least 90% of the asphalt mats were subjected to at least two roller passes. However, the number of passes required to achieve the desired density (94% to 97%) differed from project to project depending on the underlying layer. The results of these case studies show both opportunities and challenges in using IC for monitoring compaction quality during construction in real-time.

Keywords: asphalt pavement construction, density, intelligent compaction, intelligent compaction analyzer, intelligent compaction measure value

Procedia PDF Downloads 124