Search results for: rolling contact mechanic

Authors: Peyman Aela, Lu Zong, Guoqing Jing

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Recently, there has been growing interest in numerical modeling of ballast railway tracks. A commonly used mechanistic modeling approach for ballast is the discrete element method (DEM). Up to now, the effects of the contact model on ballast particle behavior have not been precisely examined. In this regard, selecting the appropriate contact model is mainly associated with the particle characteristics and the loading condition. Since ballast is cohesionless material, different contact models, including the linear spring, Hertz-Mindlin, and Hysteretic models, could be used to calculate particle-particle or wall-particle contact forces. Moreover, the simulation of a dynamic test is vital to investigate the effect of damping parameters on the ballast deformation. In this study, ballast box tests were simulated by DEM to examine the influence of different contact models on the mechanical behavior of the ballast layer under cyclic loading. This paper shows how the contact model can affect the deformation and damping of a ballast layer subjected to cyclic loading in a ballast box.

Keywords: ballast, contact model, cyclic loading, DEM

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Authors: Runliang Wang, Jianhua Liu, Duo Jia, Xiaoyu Ding

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The contact between sealing surfaces plays a vital role in guaranteeing the sealing performance of various seals. To date, analyses of sealing structures have rarely considered both structural parameters (macroscale) and surface roughness information (microscale) of sealing surfaces due to the complex modeling process. Meanwhile, most of the contact analyses applied to seals were conducted only under normal loading, which still existssome distance from real loading conditions in engineering. In this paper, a multiscale rough contact model, which took both macrostructural parameters of seals and surface roughness information of sealing surfaces into consideration for the cone-cone seal, was established. By using the finite element method (FEM), the combined normal and tangential loading was applied to the model to simulate the assembly process of the cone-cone seal. The evolution of the contact behaviors during the assembly process, such as the real contact area (RCA), the distribution of contact pressure, and contact status, are studied in detail. The results showed the non-linear relationship between the RCA and the load, which was different from the normal loading cases. In addition, the evolution of the real contact area of cone-cone seals with isotropic and anisotropic rough surfaces are also compared quantitatively.

Keywords: contact mechanics, FEM, randomly rough surface, real contact area, sealing

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Authors: Djamel Ouzandja, Boualem Tiliouine

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The safety evaluation of the concrete gravity dams subjected to seismic excitations is really very complex as the earthquake response of the concrete gravity dam depends upon its contraction joints with foundation soil. This paper presents the seismic response of concrete gravity dams considering friction contact and welded contact. Friction contact is provided using contact elements. Two-dimensional (2D) finite element model of Oued Fodda concrete gravity dam, located in Chlef at the west of Algeria, is used for this purpose. Linear and nonlinear analyses considering dam-foundation soil interaction are performed using ANSYS software. The reservoir water is modeled as added mass using the Westergaard approach. The Drucker-Prager model is preferred for dam and foundation rock in nonlinear analyses. The surface-to-surface contact elements based on the Coulomb's friction law are used to describe the friction. These contact elements use a target surface and a contact surface to form a contact pair. According to this study, the seismic analysis of concrete gravity dams including base sliding. When the friction contact is considered in joints, the base sliding displacement occurs along the dam-foundation soil contact interface. Besides, the base sliding may generally decrease the principal stresses in the dam.

Keywords: concrete gravity dam, dynamic soil-structure interaction, friction contact, sliding

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Authors: Barenten Suciu

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An electrical generator able to harness energy from the water waves and designed as a double-cone geared motor-generator (DCGMG), is proposed and theoretically investigated. Similar to a differential gear mechanism, used in the transmission system of the auto vehicle wheels, an angular speed differential is created between the cones rolling on two concentric circular rails. Water wave acting on the floating DCGMG produces and a gear-box amplifies the speed differential to gain sufficient torque for power generation. A model that allows computation of the speed differential, torque, and power of the DCGMG is suggested. Influence of various parameters, regarding the construction of the DCGMG, as well as the contact between the double-cone and rails, on the electro-mechanical output, is emphasized. Results obtained indicate that the generated electrical power can be increased by augmenting the mass of the double-cone, the span of the rails, the apex angle of the cones, the friction between cones and rails, the amplification factor of the gear-box, and the efficiency of the motor-generator. Such findings are useful to formulate a design methodology for the proposed wave-powered generator.

Keywords: amplification of angular speed differential, circular concentric rails, double-cone, wave-powered electrical generator

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Authors: Amine Beloufa, Mohamed Amirat

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In the electric vehicle, high power leads to high current; automotive power connector should resist to this high current in order to avoid a serious damage caused by the increase of contact temperature. The purpose of this paper is to analyze experimentally and numerically the effect of the cable diameter variation on the decrease of contact temperature. For this reason, a finite element model was developed to calculate the numerical contact temperature for several cable diameters and several electrical high currents. Also, experimental tests were established in order to validate this numerical model. Results show that the influence of cable diameter on the contact temperature is never neglected.

Keywords: contact temperature, experimental test, finite element, power automotive connector

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Authors: Riad Harouz, Brahim Mahfoud

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The threads and the circles on reinforced concrete are obtained by process of hot rolling with pebbles finishers in metal carbide which present a way of rolling around the outside diameter. Our observation is that this throat presents geometrical wear after the end of its cycle determined in tonnage. In our study, we have determined, in a first step, experimentally measurements of the wear in terms of thermo-mechanical parameters (Speed, Load, and Temperature) and the influence of these parameters on the wear. In the second stage, we have developed a mathematical model of lifetime useful for the prognostic of the wear and their changes.

Keywords: lifetime, metal carbides, modeling, thermo-mechanical, wear

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Authors: S. Selman, T. Gout

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Microbial keratitis is a serious complication of contact lens wear that can be vision and eye-threatening. Diverse presentations relating to contact lens wear include dry corneal surface, corneal infiltrate, ulceration, scarring, and complete corneal melt leading to perforation. Contact lens wear is a major risk factor and, as such, is an important consideration in any patient presenting with a red eye in the primary care setting. This paper aims to provide an overview of the risk factors, common organisms, and spectrum of contact lens-associated keratitis (CLAK) complications. It will highlight some of the salient points relevant to the assessment and workup of patients suspected of CLAK in the emergency department based on the recent literature and therapeutic guidelines. An overview of the management principles will also be provided.

Keywords: microbial keratitis, corneal pathology, contact lens-associated complications, painful vision loss

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Authors: Mahmoud M. Tash

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The present study was carried out to investigate the effect of alloying elements and thermo-mechanical treatment (TMT) i.e. hot rolling and forging with different reduction ratios on the hardness (HV) and impact toughness (J) of heat-treated low alloy steels. An understanding of the combined effect of TMT and alloying elements and by measuring hardness, impact toughness, resulting from different heat treatment following TMT of the low alloy steels, it is possible to determine which conditions yielded optimum mechanical properties and high strength to weight ratio. Experimental Correlations between hot work reduction ratio, hardness and impact toughness for thermo-mechanically heat treated low alloy steels are analyzed quantitatively, and both regression and mathematical hardness and impact toughness models are developed.

Keywords: hot forging, hot rolling, heat treatment, hardness (HV), impact toughness (J), microstructure, low alloy steels

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Authors: Yin-Chen Liu, Chih-Chun Wu, Mei-He Shih

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In this technology society, using ICT(Information and communications technology) to contact each other is very common. Interpersonal ICT communication maintains social support. Therefore, the study investigated the ICT communication between undergraduates and their parents, and gender differences were also detected. The sample size was 1,209 undergraduates, including 624(51.6%) males, 584(48.3%) females, and 1 gender unidentified. In the sample, 91.8% of the sample used phones to contact their fathers and 93.8% of them use phones to contact their mothers. 78.5% and 87.6% of the sample utilized LINE to contact their fathers and mothers respectively. As for Facebook, only 13.4% and 16.5% of the sample would use to contact their fathers and mothers respectively. Aforementioned results implied that the undergraduates nowadays use phone and LINE to contact their parents more common than Facebook. According to results from Pearson correlations, the more undergraduates refused to add their fathers as their Facebook friends, the more they refused to add their mothers as Facebook friends. The possible reasons for it could be that to distinguish different social network such as family and friends. Another possible reason could be avoiding parents’ controlling. It could be why the kids prefer to use phone and LINE to Facebook when contacting their parents. Result from Pearson correlations showed that the more undergraduates actively contact their fathers, the more they actively contact their mothers. On the other hand, the more their fathers actively contact them, the more their mothers actively contact them. Based on the results, this study encourages both parents and undergraduates to contact each other, for any contact between any two family members is associated with contact between other two family members. Obviously, the contact between family members is bidirectional. Future research might want to investigate if this bidirectional contact is associated with the family relation. For gender differences, results from the independent t-tests showed that compared to sons, daughters actively contacted their parents more. Maybe it is because parents keep saying that it is dangerous out there for their daughters, so they build up the habit for their daughters to contact them more. Results from paired sample t-tests showed that the undergraduates agreed that talking to mother on the phone had more satisfaction, felt more intimacy and supported than fathers.

Keywords: family ICT communication, parent-child ICT communication, FACEBOOK and LINE, gender differences

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Authors: Mehdi Assefi, Keihan Hataminezhad

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One of the efficient architectures for exploring the resources in wireless ad-hoc networks is contact-based architecture. In this architecture, each node assigns a unique zone for itself and each node keeps all information from inside the zone, as well as some from outside the zone, which is called contact. Reducing the overlap between different zones of a node and its contacts increases its performance, therefore Edge Method (EM) is designed for this purpose. Contacts selected by EM do not have any overlap with their sources, but for choosing the contact a vast amount of information must be transmitted. In this article, we will offer a new protocol for contact selection, which is called PEM. The objective would be reducing the volume of transmitted information, using Non-Uniform Dissemination Probabilistic Protocols. Consumed energy for contact selection is a function of the size of transmitted information between nodes. Therefore, by reducing the content of contact selection message using the PEM will decrease the consumed energy. For evaluation of the PEM we applied the simulation method. Results indicated that PEM consumes less energy compared to EM, and by increasing the number of nodes (level of nodes), performance of PEM will improve in comparison with EM.

Keywords: wireless ad-hoc networks, contact selection, method for CARD, energy-efficient

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Authors: Jungkyun Na, Jaesang Lee, Yang Mo Koo

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In this study to find a replacement for expensive secondary recrystallization in GO electrical steel production, effect of heat treatment on the formation of columnar grain and Goss texture is investigated. The composition of the sample is Fe-2.0Si-0.2C. This process involves repeating of cold rolling and decarburization as a replacement for secondary recrystallization. By cold-rolling shear band is made and Goss grain grows from shear band by decarburization. By doing another cold rolling, some Goss texture is newly formed from the shear band, and some Goss texture is retained in microbands. To determine whether additional heat treatment with H2 atmosphere is needed on decarburization process for growth of Goss texture, comparing between decarburization and heat treatment with H2 atmosphere is performed. Also, to find optimum condition for heat treatment, heat treatment with various time and temperature is performed. It was found that increase in the number of cold rolling and heat treatment increases Goss texture. Both high Goss texture and good columnar structure is achieved at 900℃, and this temperature is within a+r phase region. Heat treatment at a temperature higher than a+r phase region caused carbon diffusion and this made layer with Goss grain decrease.

Keywords: electrical steel, Goss texture, columnar structure, normal grain growth

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Authors: Chang He, Hiroshi Tamura, Hiroshi Katsuchi, Jiaqi Wang

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In this study, the aim is to infer the slip limit (static friction limit) of contact interfaces in bolt friction joints by analyzing other bolt friction joints with the same contact surface but in a different shape. By using the Weibull distribution to deal with microelements on the contact surface statistically, the slip limit of a certain type of bolt joint was predicted from other types of bolt joint with the same contact surface. As a result, this research succeeded in predicting the slip limit of bolt joins with different numbers of contact surfaces and with different numbers of bolt rows.

Keywords: bolt joints, slip coefficient, finite element method, Weibull distribution

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Authors: P. R. Prabhu, S. M. Kulkarni, S. S. Sharma, K. Jagannath, Achutha Kini U.

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In the present study, response surface methodology has been used to optimize turn-assisted deep cold rolling process of AISI 4140 steel. A regression model is developed to predict surface hardness and surface roughness using response surface methodology and central composite design. In the development of predictive model, deep cold rolling force, ball diameter, initial roughness of the workpiece, and number of tool passes are considered as model variables. The rolling force and the ball diameter are the significant factors on the surface hardness and ball diameter and numbers of tool passes are found to be significant for surface roughness. The predicted surface hardness and surface roughness values and the subsequent verification experiments under the optimal operating conditions confirmed the validity of the predicted model. The absolute average error between the experimental and predicted values at the optimal combination of parameter settings for surface hardness and surface roughness is calculated as 0.16% and 1.58% respectively. Using the optimal processing parameters, the hardness is improved from 225 to 306 HV, which resulted in an increase in the near surface hardness by about 36% and the surface roughness is improved from 4.84µm to 0.252 µm, which resulted in decrease in the surface roughness by about 95%. The depth of compression is found to be more than 300µm from the microstructure analysis and this is in correlation with the results obtained from the microhardness measurements. Taylor Hobson Talysurf tester, micro Vickers hardness tester, optical microscopy and X-ray diffractometer are used to characterize the modified surface layer.

Keywords: hardness, response surface methodology, microstructure, central composite design, deep cold rolling, surface roughness

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Authors: Tsukasa Ogawa, Mitsuhiro Okayasu

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To examine the generation properties of electric power for piezoelectric (PbZrTiO3) ceramic plates, the electric-power generation characteristics were examined experimentally and numerically during cyclic bending under various loading fixtures with different contact condition, i.e., point and area contact. In the low applied loading condition between 10 and 50 N, increasing the load-contact area on the piezoelectric ceramic led to a nonlinear decrease in the generated voltage. Decreasing contact area, including the point contact, basically enhanced the generated voltage, although the voltage saturated during loading when the contact area is less than ϕ5 mm, which was attributed to the high strain status, resulting in the material failure, i.e., high stress concentration. In this case, severe plastic deformation and the domain switching were dominated failure modes in the ceramic. From this approach, it is clear that the applied load became more larger (50 ~100 N), larger contact area (ϕ10 ~ ϕ20 mm) became advantageous for power generation. Based upon this cyclic loading was carried out to investigate the fatigue characteristics of the piezoelectric ceramic late. For all contact conditions, electric voltage dropped in the beginning of the cyclic loading, although the higher electric generation was stable in the further cyclic loading for the contact area of ϕ10 ~ ϕ20 mm. In constant, further decrement of electric generation occurred for the point contact condition, and the low electric voltage was generated for the larger contact condition.

Keywords: electric power generation, piezoelectric ceramic, lead zirconate titanate ceramic, loading conditions

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Authors: Humberto Miranda, Haroldo G. Santana, Gabriel A. Paz, Vicente P. Lima, Jeffrey M. Willardson

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Foam rolling is a practice that has increased in popularity before and after strength training. The purpose of this study was to compare the acute effects of different foam rolling periods for the lower body muscles on subsequent performance (total repetitions and training volume), myoelectric activity and rating of perceived exertion in trained men. Fourteen trained men (26.2 ± 3.2 years, 178 ± 0.04 cm height, 82.2 ± 10 kg weight and body mass index 25.9 ± 3.3kg/m2) volunteered for this study. Four repetition maximum (4-RM) loads were determined for hexagonal bar deadlift and 45º angled leg press during test and retest sessions over two nonconsecutive days. Five experimental protocols were applied in a randomized design, which included: a traditional protocol (control)—a resistance training session without prior foam rolling; or resistance training sessions performed following one (P1), two (P2), three (P3), or four (P4) sets of 30 sec. foam rolling for the lower extremity musculature. Subjects were asked to roll over the medial and lateral aspects of each muscle group with as much pressure as possible. All foam rolling was completed at a cadence of 50 bpm. These procedures were performed on both sides unilaterally as described below. Quadriceps: between the apex of the patella and the ASIS; Hamstring: between the gluteal fold and popliteal fossa; Triceps surae: between popliteal fossa and calcaneus tendon. The resistance training consisted of five sets with 4-RM loads and two-minute rest intervals between sets, and a four-minute rest interval between the hexagonal bar deadlift and the 45º angled leg press. The number of repetitions completed, the myoelectric activity of vastus lateralis (VL), vastus medialis oblique (VMO), semitendinosus (SM) and medial gastrocnemius (GM) were recorded, as well as the rating of perceived exertion for each protocol. There were no differences between the protocols in the total repetitions for the hexagonal bar deadlift (Control - 16.2 ± 5.9; P1 - 16.9 ± 5.5; P2 - 19.2 ± 5.7; P3 - 19.4 ± 5.2; P4 - 17.2 ± 8.2) (p > 0.05) and 45º angled leg press (Control - 23.3 ± 9.7; P1 - 25.9 ± 9.5; P2 - 29.1 ± 13.8; P3 - 28.0 ± 11.7; P4 - 30.2 ± 11.2) exercises. Similar results between protocols were also noted for myoelectric activity (p > 0.05) and rating of perceived exertion (p > 0.05). Therefore, the results of the present study indicated no deleterious effects on performance, myoelectric activity and rating of perceived exertion responses during lower body resistance training.

Keywords: self myofascial release, foam rolling, electromyography, resistance training

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Authors: Narges Shayesteh Moghaddam

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Tungsten (W), a refractory metal known for its remarkably high melting temperature, offers tremendous potential for use in challenging environments prevalent in sectors such as space exploration, defense, and nuclear industries. Additive manufacturing, especially the Laser Powder-Bed Fusion (LPBF) technique, emerges as a beneficial method for fabricating tungsten parts. This technique enables the production of intricate components while simultaneously reducing production lead times and associated costs. However, the inherent brittleness of tungsten and its tendency to crack under high-temperature conditions pose significant challenges to the manufacturing process. Our research primarily focuses on the process of rolling tungsten parts in a layer-by-layer manner in LPBF and the subsequent changes in microstructure. Our objective is not only to identify the alterations in the microstructure but also to assess their implications on the physical properties and performance of the fabricated tungsten parts. To examine these aspects, we conducted an extensive series of experiments that included the fabrication of tungsten samples through LPBF and subsequent characterization using advanced materials analysis techniques. These investigations allowed us to scrutinize shifts in various microstructural features, including, but not limited to, grain size and grain boundaries occurring during the rolling process. The results of our study provide crucial insights into how specific factors, such as plastic deformation occurring during the rolling process, influence the microstructural characteristics of the fabricated parts. This information is vital as it provides a foundation for understanding how the parameters of the layer-by-layer rolling process affect the final tungsten parts. Our research significantly broadens the current understanding of microstructural evolution in tungsten parts produced via the layer-by-layer rolling process in LPBF. The insights obtained will play a pivotal role in refining and optimizing manufacturing parameters, thus improving the mechanical properties of tungsten parts and, therefore, enhancing their performance. Furthermore, these findings will contribute to the advancement of manufacturing techniques, facilitating the wider application of tungsten parts in various high-demand sectors. Through these advancements, this research represents a significant step towards harnessing the full potential of tungsten in high-temperature and high-stress applications.

Keywords: additive manufacturing, rolling, tungsten, refractory materials

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Authors: T. Bensana, S. Mekhilef

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The methodology of vibration based condition monitoring technology has been developing at a rapid stage in the recent years suiting to the maintenance of sophisticated and complicated machines. The ability of wavelet analysis to efficiently detect non-stationary, non-periodic, transient features of the vibration signal makes it a demanding tool for condition monitoring. This paper presents a methodology for fault diagnosis of rolling element bearings based on wavelet envelope power spectrum technique is analysed in both the time and frequency domains. In the time domain the auto-correlation of the wavelet de-noised signal is applied to evaluate the period of the fault pulses. However, in the frequency domain the wavelet envelope power spectrum has been used to identify the fault frequencies with the single sided complex Laplace wavelet as the mother wavelet function. Results show the superiority of the proposed method and its effectiveness in extracting fault features from the raw vibration signal.

Keywords: preventive maintenance, fault diagnostics, rolling element bearings, wavelet de-noising

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Authors: Soumendu Monia, Vaibhav Jain, Hrishikesh Jugade, Manashi Adhikary, Goutam Mukhopadhyay

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'Rolled in scale' (RIS) and 'Rolled in Scum' (RISc) are two superficial surface defects on cold rolled and annealed steel sheets which affect the aesthetics of surface and thereby that of the end-product. Both the defects are believed to be originating from distinctly different sources having different mechanisms of formation. However, due to their similar physical appearance, RIS and RISc are generally confused with each other and hence attaining the exact root cause for elimination of the defect becomes difficult. RIS appears irregular in shape, sometimes scattered, and always oriented in rolling direction. RISc is generally oval shaped, having identifiable pointed edges and mostly oriented in rolling direction. Visually, RIS appears to be greyish in colour whereas RISc is whitish in colour. Both the defects have quite random occurrence and do not leave any imprints on the reverse-side of the sheet. In the current study, an attempt has been made to differentiate these two similar looking surface defects using various metallographic and characterization techniques. Systematic experiments have been carried out to identify possible mechanisms of formation of these defects. Detailed characterization revealed basic differences between RIS and RISc with respect to their surface morphology. To summarize, RIS was observed as a residue of an otherwise under-pickled scale patch on surface, after it has been subjected to cold rolling and annealing in a batch/continuous furnace. Whereas RISc was found to be a localized rubbing of the surface, at the time of cold rolling itself, resulting in a rough surface texture.

Keywords: annealing, rolled in scale, rolled in scum, skin panel

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Authors: A. Sakavičius, A. Lukša, V. Nargelienė, V. Bukauskas, G. Astromskas, A. Šetkus

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We investigate the influence of annealing on the properties of a contact between graphene and metal (Au and Ni), using circular transmission line model (CTLM) contact geometry. Kelvin probe force microscopy (KPFM) and Raman spectroscopy are applied for characterization of the surface and interface properties. Annealing causes a decrease of the metal-graphene contact resistance for both Ni and Au.

Keywords: Au/Graphene contacts, graphene, Kelvin force probe microscopy, NiC/Graphene contacts, Ni/Graphene contacts, Raman spectroscopy

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Authors: Roman Koky, Sylvie Graf

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The relationship between the Roma and members of the majority is tense across Europe due to the fact that the Roma people are the most stigmatized minorities. Studies show that Roma is discriminated against on all levels of society. Improving intergroup relations between the Roma and members of the majority (i.e., non-Roma) is thus one of the most pressing issues of social psychological research. Intergroup contact theory is one of the most effective strategies for improving intergroup relations. However, current research has some limitations, such as the fact that most researchers focus primarily on the perspective of the majority, while the perspective of minorities (e.g., the Roma) is largely missing. Due to the persisting segregation of Roma, and thus the lack of opportunities for direct intergroup contact between the Roma and the majority, using direct intergroup contact as an intervention to reduce prejudice is difficult. In this research, we, therefore, focused on the effect of indirect forms of intergroup contact, particularly extended contact (i.e., experiences with outgroup members shared by fellow ingroup members such as friends or family). Extended contact functions as a descriptive social norm that informs about the actual amount of contact in one’s environment. In a group of Czech Roma (N = 226), the descriptive social norm was associated with ingroup injunctive social norm (e.g., the perceived support of intergroup contact with non-Roma by fellow ingroup members) and lower amount of prejudice toward the non-Roma. We discuss the findings with respect to possibilities to improve the relations between Roma and members of the majority across Europe.

Keywords: intergroup contact, prejudice, majority, minority, social norms

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Authors: A. Pesin, D. Pustovoytov, A. Kolesnik, M. Sverdlik

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Rolling disturbances often arise which might lead to defects such as nonflatness, warpage, corrugation, etc. Numerous methods of compensation for such disturbances are well known. However, most of them preserve the initial form of transverse flow of the strip, such as convex, concave or asymmetric (for example, sphenoid). Sometimes, the form inherited (especially asymmetric) is undesirable. Technical solutions have been developed which include providing conditions for transverse metal flow in deformation zone. It should be noted that greater reduction is followed by transverse flow increase, while less reduction causes a corresponding decrease in metal flow for differently deformed metal lengths to remain approximately the same and in order to avoid the defects mentioned above. One of the solutions suggests sequential strip deforming from rectangular cross-section profile with periodical rectangular grooves back into rectangular profile again. The work was carried out in DEFORM 3D program complex. Experimental rolling was performed on laboratory mill 150. Comparison of experimental and theoretical results demonstrated good correlation.

Keywords: FEM, cross-section deformation, mechanical engineering, applied mechanics

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Authors: Arvind Dhingra, Tejinder Singh Saggu

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As the energy demands rise and the pollution levels grow, it becomes imperative for us to save energy in all the fields in which it is used. The industrial sector is the major commercial energy consuming sector in India, where electrical energy is the most common and widely used type of energy. As the demand and price of energy are increasing day by day, therefore, the subject of energy conservation is a concern for most energy users particularly industry. Judicious use of energy becomes imperative for third world developing country being presence of energy crisis. This paper provides some measure for energy saving that can be commonly recommended for a rolling unit of steel industry. A case of hot rolling unit in JSL Stainless Ltd., Hisar for energy conservation is given. Overall improvement in energy consumption in light of the stated recommendation is illustrated along with the proposed utilization of the techniques and their applications. Energy conservation in conventional motor with replacement or use of star delta star converter, reduction in cable losses, replacement of filament of LED lamps, replacement of conventional transformer with cast resin dry type transformer and provision of energy management system for energy conservation and per unit production cost reduction are elaborated in this paper.

Keywords: energy audit, energy conservation, energy efficient motors

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Authors: Henry Ogbemudia Omoregbee, Mabel Usunobun Olanipekun

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Debris fault diagnosis based on acoustic signals in rolling element bearing running at low speed and high radial loads are more of low amplitudes, particularly in the case of debris faults whose signals necessitate high sensitivity analyses. As the rollers in the bearing roll over debris trapped in grease used to lubricate the bearings, the envelope signal created by amplitude demodulation carries additional diagnostic information that is not available through ordinary spectrum analysis of the raw signal. The kurtosis value obtained for three different scenarios (debris induced, outer crack induced, and a normal good bearing) couldn't be used to easily identify whether the used bearings were defective or not. It was established in this work that the envelope spectrum analysis detected the fault signature and its harmonics induced in the debris bearings when bandpass filtering of the raw signal with the frequency band specified by kurtogram and spectral kurtosis was made.

Keywords: rolling bearings, rolling element bearing noise, bandpass filtering, harmonics, envelope spectrum analysis, spectral kurtosis

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Authors: Guillaume Craveur

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This study shows the opportunity to use numerical tools dedicated to Fire Safety Engineering for the Rolling Stock. Indeed, some lawful requirements can now be demonstrated by using numerical tools. The first part of this study presents the use of modelling evacuation tool to satisfy the criteria of evacuation time for the rolling stock. The buildingEXODUS software is used to model and simulate the evacuation of rolling stock. Firstly, in order to demonstrate the reliability of this tool to calculate the complete evacuation time, a comparative study was achieved between a real test and simulations done with buildingEXODUS. Multiple simulations are performed to capture the stochastic variations in egress times. Then, a new study is done to calculate the complete evacuation time of a train with the same geometry but with a different interior architecture. The second part of this study shows some applications of Computational Fluid Dynamics. This work presents the approach of a multi scales validation of numerical simulations of standardized tests with Fire Dynamics Simulations software developed by the National Institute of Standards and Technology (NIST). This work highlights in first the cone calorimeter test, described in the standard ISO 5660, in order to characterize the fire reaction of materials. The aim of this process is to readjust measurement results from the cone calorimeter test in order to create a data set usable at the seat scale. In the second step, the modelisation concerns the fire seat test described in the standard EN 45545-2. The data set obtained thanks to the validation of the cone calorimeter test was set up in the fire seat test. To conclude with the third step, after controlled the data obtained for the seat from the cone calorimeter test, a larger scale simulation with a real part of train is achieved.

Keywords: fire safety engineering, numerical tools, rolling stock, multi-scales validation

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Authors: Mohammed Tahir, Jonas Lagergren

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Vancron 40, a nitrided powder metallurgical tool Steel, is used in cold work applications where the predominant failure mechanisms are adhesive wear or galling. Typical applications of Vancron 40 are among others fine blanking, cold extrusion, deep drawing and cold work rolls for cluster mills. Vancron 40 positive results for cold work rolls for cluster mills and as a tool for some severe metal forming process makes it competitive compared to other type of work rolls that require higher precision, among others in cold rolling of thin stainless steel, which required high surface finish quality. In this project, three roll materials for cold rolling of stainless steel strip was examined, Vancron 40, Narva 12B (a high-carbon, high-chromium tool steel alloyed with tungsten) and Supra 3 (a Chromium-molybdenum tungsten-vanadium alloyed high speed steel). The purpose of this project was to study the depth profiles of the ironed stainless steel strips, emergence of galling and to study the lubrication performance used by steel industries. Laboratory experiments were conducted to examine scratch of the strip, galling and surface roughness of the roll materials under severe tribological conditions. The critical sliding length for onset of galling was estimated for stainless steel with four different lubricants. Laboratory experiments result of performance evaluation of resistance capability of rolls toward adhesive wear under severe conditions for low and high reductions. Vancron 40 in combination with cold rolling lubricant gave good surface quality, prevents galling of metal surfaces and good bearing capacity.

Keywords: Vancron 40, cold rolling, adhesive wear, galling, surface finish, lubricant, stainless steel

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Authors: Nicola Menga, Giuseppe Carbone

Abstract:

Although contact mechanics has been widely focused on the study of contacts between half-space, it has been recently pointed out that in presence of finite thickness elastic layers the results of the contact problem show significant difference in terms of the main contact quantities (e.g. contact area, penetration, mean pressure, etc.). Actually, there exist a wide range of industrial application demanding for this kind of studies, such as seals leakage prediction or pressure-sensitive coatings for electrical applications. In this work, we focus on the contact between a rigid profile and an elastic layer of thickness h confined under two different configurations: rigid constrain and applied uniform pressure. The elastic problem at hand has been formalized following Green’s function method and then numerically solved by means of a matrix inversion. We study different contact conditions, both considering and neglecting adhesive interactions at the interface. This leads to different solution techniques: Adhesive contacts equilibrium solution is found, in term of contact area for given penetration, making stationary the total free energy of the system; whereas, adhesiveless contacts are addressed defining an equilibrium criterion, again on the contact area, relying on the fracture mechanics stress intensity factor KI. In particular, we make the KI vanish at the edges of the contact area, as peculiar for adhesiveless elastic contacts. The results are obtained in terms of contact area, penetration, and mean pressure for both adhesive and adhesiveless contact conditions. As expected, in the case of a uniform applied pressure the slab turns out much more compliant than the rigidly constrained one. Indeed, we have observed that the peak value of the contact pressure, for both the adhesive and adhesiveless condition, is much higher for the rigidly constrained configuration than in the case of applied uniform pressure. Furthermore, we observed that, for little contact area, both systems behave the same and the pull-off occurs at approximately the same contact area and mean contact pressure. This is an expected result since in this condition the ratio between the layers thickness and the contact area is very high and both layer configurations recover the half-space behavior where the pull-off occurrence is mainly controlled by the adhesive interactions, which are kept constant among the cases.

Keywords: contact mechanics, adhesion, friction, thick layer

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Authors: Sunthorn Sittisakuljaroen

Abstract:

The edge waviness in hot rolled steel is a common defect. Variables that effect for such defect include as raw material and machine. These variables are necessary to consider. This research studied the defect of edge waviness for SS 400 of metal sheet manufacture. Defect of metal sheets divided into two groups. The specimens were investigated on chemical composition and mechanical properties to find the difference. The results of investigate showed that not different to a standard significantly. Therefore the roll milled machine for sample need to adjustable rollers for press on metal sheet which was more appropriate to adjustable at both ends.

Keywords: edge waviness, hot rolling steel, metal sheet defect, SS 400, roll leveller

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Authors: Ravi Prasher

Abstract:

In nanostructured material thermal transport is dominated by contact resistance. Theoretical models describing thermal transport at interfaces assume perfectly flat surface whereas in reality surfaces can be rough with roughness ranging from sub-nanoscale dimension to micron scale. Here we introduce a model which includes both nanoscale contact mechanics and nanoscale heat transfer for rough nanoscale surfaces. This comprehensive model accounts for the effect of phonon acoustic mismatch, mechanical properties, chemical properties and randomness of the rough surface.

Keywords: adhesion and contact resistance, Kaptiza resistance of rough surfaces, nanoscale thermal transport

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Authors: Takahiro Ishizaki, Shutaro Hisada, Oi Lun Li

Abstract:

Control of surface wettability is very important in various industrial fields. Thus, contact angle hysteresis which is defined as the difference between advancing and receding water contact angles has been paid attention because the surface having low contact angle hysteresis can control wetting behavior of water droplet. Self-assembled monolayer (SAM) formed using organic silane molecules has been used to control surface wettability, in particular, static contact angles, however, the effect of alkyl-chain length in organic silane molecules on the contact angle hysteresis has not yet clarified. In this study, we aimed to investigate the effect of alkyl-chain length (C1-C18) in organic silane molecules on the contact angle hysteresis. SAMs were formed on Si wafer by thermal CVD method using silane coupling agents having different alkyl-chain length. The static water contact angles increased with an increase in the alkyl-chain length. On the other hand, although the water contact angle hysteresis tended to decrease with an increase in the alkyl-chain length, in case of the alkyl-chain length of more than C16 the contact angle hysteresis increased. This could be due to the decrease in the molecular mobility because of the increase in the molecular packing density in chemisorbed silane molecules.

Keywords: alkyl-chain length, self-assembled monolayer, silane coupling agent, surface wettability

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Authors: Thierno Diop, Michel Fortin, Jean Deteix

Abstract:

Since the precise formulation of the elastic part is irrelevant for the description of the algorithm, we shall consider a generic case. In practice, however, we will have to deal with a non linear material (for instance a Mooney-Rivlin model). We are interested in solving a finite element approximation of the problem, leading to large-scale non linear discrete problems and, after linearization, to large linear systems and ultimately to calculations needing iterative methods. This also implies that penalty method, and therefore augmented Lagrangian method, are to be banned because of their negative effect on the condition number of the underlying discrete systems and thus on the convergence of iterative methods. This is in rupture to the mainstream of methods for contact in which augmented Lagrangian is the principal tool. We shall first present the problem and its discretization; this will lead us to describe a general solution algorithm relying on a preconditioner for saddle-point problems which we shall describe in some detail as it is not entirely standard. We will propose an iterative approach for solving three-dimensional frictional contact problems between elastic bodies, including contact with a rigid body, contact between two or more bodies and also self-contact.

Keywords: frictional contact, three-dimensional, large-scale, iterative method

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