Search results for: welding seam

Authors: H. Pasternak, T. Krausche

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The Porsche Pavilion is an innovative stainless steel construction using the principle, often used in ship and car design, as an advantage for building a light but stiff structure. The Pavilion is a one of a kind and outstanding construction that you can find. It fits right in the existing parts of the Autostadt within the lagoon landscape and was built in only eight months. With its curving lines and exiting bends the structure is an extraordinary work which was designed by Henn architects, Munich. The monocoque has a good balance between material and support structure. The stiffness is achieved by the upper and lower side sheathing plates and the intermediate formers. Also the roof shell has no joints and a smooth surface. The assembling of the structure requires a large time and effort cost due to many welds which are necessary to connect all section to one large shell.

Keywords: construction welding, exhibition building, light steel construction, monocoque

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Authors: Karthik K. R, Viswanath V, Asraff A. K

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The first stage of a new-generation launch vehicle of ISRO makes use of large pressure vessels made of Aluminium alloy AA2219 to store fuel and oxidizer. These vessels have many weld joints that may contain cracks or crack-like defects during their fabrication. These defects may propagate across the vessel during pressure testing or while in service under the influence of tensile stresses leading to catastrophe. Though ductile materials exhibit significant stable crack growth prior to failure, it is not generally acceptable for an aerospace component. There is a need to predict the initiation of stable crack growth. The structural integrity of the vessel from fracture considerations can be studied by constructing the Failure Assessment Diagram (FAD) that accounts for both brittle fracture and plastic collapse. Critical crack sizes of the pressure vessel may be highly conservative if it is predicted from FAD alone. If the J-R curve for material under consideration is available apriori, the critical crack sizes can be predicted to a certain degree of accuracy. In this paper, a novel approach is proposed to predict the integrity of a weld in a pressure vessel made of AA2219 material. Fracture parameter ‘J-integral’ at the crack front, evaluated through finite element analyses, is used in the new procedure. Based on the simulation of tension tests carried out on SCT specimens by NASA, a cut-off value of J-integral value (J?ᵤₜ_ₒ??) is finalised. For the pressure vessel, J-integral at the crack front is evaluated through FE simulations incorporating different surface cracks at long seam weld in a cylinder and in dome petal welds. The obtained J-integral, at vessel level, is compared with a value of J?ᵤₜ_ₒ??, and the integrity of vessel weld in the presence of the surface crack is firmed up. The advantage of this methodology is that if SCT test data of any metal is available, the critical crack size in hardware fabricated using that material can be predicted to a better level of accuracy.

Keywords: FAD, j-integral, fracture, surface crack

Procedia PDF Downloads 158

Authors: Kuen-Ming Shu, Cheng-Yu Chen

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A vibrating-fork sensor can measure the level height of solids and liquids and operates according to the principle that vibrations created by piezoelectric ceramics are transmitted to the vibrating fork, which produces resonance. When the vibrating fork touches an object, its resonance frequency changes and produces a signal that returns to a controller for immediate adjustment, so as to effectively monitor raw material loading. The design of the vibrating fork in a vibrating-fork material sensor is crucial. In this paper, ANSYS finite element analysis software is used to perform modal analysis on the vibrations of the vibrating fork. In addition, to design and produce a superior vibrating fork, the dimensions and welding shape of the vibrating fork are compared in a simulation performed using the Taguchi method.

Keywords: vibrating fork, piezoelectric ceramics, sound wave, ANSYS, Taguchi method, modal analysis

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Authors: Richard E. Miller

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12.7-mm thick plates of 6061-T6511 aluminum alloy and high hardness steel (528 HV) were successfully joined by a friction stir bonding process using a tungsten-rhenium stir tool. Process parameter variation experiments, which included tool design geometry, plunge and traverse rates, tool offset, spindle tilt, and rotation speed, were conducted to develop a parameter set which yielded a defect free joint. Laboratory tensile tests exhibited yield stresses which exceed the strengths of comparable AA6061-to-AA6061 fusion and friction stir weld joints. Scanning electron microscopy and energy dispersive X-ray spectroscopy analysis also show atomic diffusion at the material interface region.

Keywords: dissimilar materials, friction stir, welding, materials science

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Authors: Vinod Kumar, Arun Kumar, Surjit Angra

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This paper addresses the junction stress analysis of orthogonally intersecting thin walled cylindrical shell and thin walled cylindrical nozzle subjected to external loading on nozzle. Junction stresses have been calculated theoretically by welding research council (WRC) bulletins 107 and 297 for different nozzle loads. WRC bulletins 107 and 297 have been used by design engineers for calculating nozzle-vessel junction stresses since their publication. They give simple empirical relations and easy in application. Also 3D FEA in which material is elastic has been done in ANSYS software with 8 node solid element model and results of FEA have been compared with WRC results. Stress intensities obtained by WRC 297 are generally slightly higher than obtained by WRC 107. Membrane stresses obtained by FEA are much higher than WRC and membrane plus bending stresses obtained by FEA are lower than WRC.

Keywords: FEA, junction stress, solid element, WRC 107, WRC 297

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Authors: JongWon Han, NoHoon Kim, HyoIk Ahn, HaeWoo Lee

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In this study, shielded metal arc welding was performed as a function of Nb content at 2.24 wt%, 3.25 wt%, and 4.26 wt%. The microstructure was observed using scanning electron microscopy/energy dispersive X-ray spectroscopy (SEM/EDS) and showed the development of a columnar dendrite structure in the specimen having the least Nb content. From the hardness test, the hardness value was confirmed to reduce with decreasing Nb content. From electron backscatter diffraction (EBSD) analysis, the largest grain size was found in the specimen with Nb content of 2.24 wt%. The potentiodynamic polarization test was carried out to determine the pitting corrosion resistance; there was no significant difference in the pitting corrosion resistance with increasing Nb content. To evaluate the degree of sensitization to intergranular corrosion, the Double Loop Electrochemical Potentiodynamic Reactivation(DL-EPR test) was conducted. A similar degree of sensitization was found in two specimens except with a Nb content of 2.24 wt%, while a relatively high degree of sensitization was found in the specimen with a Nb content of 2.24 wt%.

Keywords: inconel 625, Nb content, potentiodynamic test, DL-EPR test

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Authors: H. Zedira, M. T. Hannachi, H. Djebaili, B. Daheche

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The rapid pace of technology development and strong competition in the market, prompted us to consider the field of manufacturing of steel pipes by a process complies fully with the requirements of industrial induction welding is high frequency (HF), this technique is better known today in Algeria, more precisely for the manufacture of tubes diameters Single Annabib TG Tebessa. The aim of our study is based on the characterization of processes controlling the mechanical behavior of steel pipes (type E24-2), welded by high frequency induction, considering the different tests and among the most destructive known test internal pressure. The internal pressure test is performed according to the application area of welded pipes, or as leak test, either as a test of strength (bursting). All tubes are subjected to a hydraulic test pressure of 50 bar kept at room temperature for a period of 6 seconds. This study provides information that helps optimize the design and implementation to predict the behavior of the tubes during operation.

Keywords: castem, pressure, stress, tubes, thickness

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Authors: Xiangchun Wang, Lihui Zheng, Maozong Gan, Peng Zhang, Tong Wu, An Chang

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The deep coal measure tight gas reservoir in Sulige is usually reformed by fracturing, because the reservoir thickness is small, the water layers can be easily communicated during fracturing, which will lead to water production of gas wells and lower production of gas wells. Therefore, it is necessary to control water during fracturing in deep coal measure tight gas reservoir. Using fuzzy-ball fluid to control water fracturing can not only increase the output but also reduce the water output. The fuzzy-ball fluid was prepared indoors to carry out evaluation experiments. The fuzzy ball fluid was mixed in equal volume with the pre-fluid and formation water to test its compatibility. The core displacement device was used to test the gas and water breaking through the matrix and fractured cores blocked by fuzzy-ball fluid. The breakthrough pressure of the plunger tests its water blocking performance. The experimental results show that there is no precipitation after the fuzzy-ball fluid is mixed with the pad fluid and the formation water, respectively. The breakthrough pressure gradients of gas and water after the fuzzy-ball fluid plugged the cracks were 0.02MPa/cm and 0.04MPa/cm, respectively, and the breakthrough pressure gradients of gas and water after the matrix was plugged were 0.03MPa/cm and 0.2MPa/cm, respectively, which meet the requirements of field operation. Two wells A and B in the Sulige Gas Field were used on site to implement water control fracturing. After the pre-fluid was injected into the two wells, 50m3 of fuzzy-ball fluid was pumped to plug the water. The construction went smoothly. After water control and fracturing, the average daily output in 161 days was increased by 13.71% and 6.99% compared with that of adjacent wells in the same layer. The adjacent wells were bubbled for 3 times and 63 times respectively, while there was no effusion in A and B construction wells. The results show that fuzzy-ball fluid is a water plugging material suitable for water control fracturing in tight gas wells, and its water control mechanism can also provide a new idea for the development of water control fracturing materials.

Keywords: coal seam, deep layer, fracking, fuzzy-ball fluid, reservoir reconstruction

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Authors: Viranshu Kumar, Hitesh Arora, Pradeep Joshi

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SS 304 is Austenitic stainless steel with Chromium and Nickel as basic constituents. It has excellent corrosion resistance properties and very good weldability. Austenitic stainless steels have superior mechanical properties at high temperatures and are used extensively in a range of applications. SS 304L has wide applications in various industries viz. Nuclear, Pharmaceutical, marine, chemical etc. due to its excellent applications and ease of joining this material has become very popular for fabrication as well as weld surfacing. Austenitic stainless steels have a tendency to form chromium depleted zones at the grain boundaries during welding and heat treatment, where chromium combines with available carbon in the vicinity of the grain boundaries, to produce an area depleted in chromium, and thus becomes susceptible to intergranular corrosion. This phenomenon is known as sensitization.

Keywords: sensitization, SS 304, GTAW, mechanical properties, carbideprecipitationHAZ, microstructure, micro hardness, tensile strength

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Authors: Brandtner-Hafner Martin

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Adhesives have established themselves as an innovative joining technology in the industry. Their strengths lie in joining different materials, avoiding structural weakening as in welding or screwing, and enabling lightweight construction methods. Now there are a variety of ways to improve the efficiency and effectiveness of bonded joints. One way is to add fiber fillers. This leads to an improvement in adhesion and cohesion (structural integrity). In this study, the effectiveness of fiber-modified adhesives for bonding different construction materials is reviewed. A series of experimental tests were performed using the fracture analytical GF principle to study the adhesive bonding safety and performance of the joint. Three different structural adhesive systems based on epoxy, CA/A hybrid, and PUR were modified with different fiber materials on different substrates. The results show that significant performance improvements can be achieved and that bonding reliability can be sustainably increased.

Keywords: fiber-modified adhesives, bonding safety, GF-principle, fracture analysis

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Authors: Gurmeet Singh Cheema, Navjotinder Singh, Gurjinder Singh, Amardeep Singh

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Aluminium and its alloys play have excellent corrosion resistant properties, ease of fabrication and high specific strength to weight ratio. In this investigation an attempt has been made to study the effect of different post weld heat treatment methods on the mechanical and metallurgical properties of TIG welded joints of the commercial aluminium alloy. Three different methods of post weld heat treatments are, solution heat treatment, artificial aged and combination of solution heat treatment and artificial aging are given to TIG welded aluminium joints. Mechanical and metallurgical properties of as welded and post weld treated joints of the aluminium alloys was examined.

Keywords: aluminium alloys, TIG welding, post weld heat treatment

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Authors: O. Hinrichs, H. Franz, G. Reiter

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Electron guns have a key function in a series of thermal processes, like EB (electron beam) melting, evaporation or welding. These techniques need a high-intensity continuous electron beam that defocuses itself due to high space charge forces. A proper beam transport throughout the magnetic focusing system can be ensured by a space charge compensation via residual gas ions. The different pressure stages in the EB gun cause various degrees of compensation. A numerical model was installed to simulate realistic charge distributions within the beam by using CST-Particle Studio code. We will present current status of beam dynamic simulations. This contribution will focus on the creation of space charge ions and their influence on beam and gun components. Furthermore, the beam transport in the gun will be shown for different beam parameters. The electron source allows to produce beams with currents of 3 A to 15 A and energies of 40 keV to 45 keV.

Keywords: beam dynamic simulation, space charge compensation, thermionic electron source, EB melting, EB thermal processing

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Authors: Kuen-Ming Shu, Jyun-Wei Chen

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Encapsulated O-rings are specifically designed to address the problem of sealing the most hostile chemicals and extreme temperature applications. Ultrasonic vibration hot embossing and ultrasonic welding techniques provide a fast and reliable method to fabricate encapsulated O-ring. This paper performs the design and analysis method of the acoustic horns with double extrusion to process tube double side flange simultaneously. The paper deals with study through Finite Element Method (FEM) of ultrasonic stepped horn used to process a capsulated O-ring, the theoretical dimensions of horns, and their natural frequencies and amplitudes are obtained through the simulations of COMOSOL software. Furthermore, real horns were fabricated, tested and verified to proof the practical utility of these horns.

Keywords: encapsulated O-rings, ultrasonic vibration hot embossing, flange making, acoustic horn, finite element analysis

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Authors: Lydia Chan, Islam Shyha, Dale Dreyer, John Hamilton, Phil Hackney

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Nickel-based superalloys are generally known to be difficult to cut due to their strength, low thermal conductivity, and high work hardening tendency. Superalloy such as alloy 625 is often used in the oil and gas industry as a surfacing material to provide wear and corrosion resistance to components. The material is typically applied onto a metallic substrate through weld overlay cladding, an arc welding technique. Cladded surfaces are always rugged and carry a tough skin; this creates further difficulties to the machining process. The present work utilised design of experiment to optimise the internal cylindrical rough turning for weld overlay surfaces. An L27 orthogonal array was used to assess effects of the four selected key process variables: cutting insert, depth of cut, feed rate, and cutting speed. The optimal cutting conditions were determined based on productivity and the level of tool wear.

Keywords: cylindrical turning, nickel superalloy, turning of overlay, weld overlay

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Authors: Yuan-Ching Lin, Sin-Yu Chen, Pei-Yu Wu

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This study reports the improvement in the wear performance of A6061 aluminum alloy clad with mixed powders of titanium carbide (TiC), copper (Cu) and aluminum (Al) using the gas tungsten arc welding (GTAW) method. The wear performance of the A6061 clad layers was evaluated by performing pin-on-disc mode wear test. Experimental results clearly indicate an enhancement in the hardness of the clad layer by about two times that of the A6061 substrate without cladding. Wear test demonstrated a significant improvement in the wear performance of the clad layer when compared with the A6061 substrate without cladding. Moreover, the interface between the clad layer and the A6061 substrate exhibited superior metallurgical bonding. Due to this bonding, the clad layer did not spall during the wear test; as such, massive wear loss was prevented. Additionally, massive oxidized particulate debris was generated on the worn surface during the wear test; this resulted in three-body abrasive wear and reduced the wear behavior of the clad surface.

Keywords: GTAW、A6061 aluminum alloy, 、surface modification, tribological study, TiC powder cladding

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Authors: Cihan Çetinkaya, Eren Özceylan, Kerem Elibal

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This paper presents a solution method for selection of production facility. The motivation has been taken from a real life case, an automotive subcontractor which has two production facilities at different cities and parts. The problem is to decide which part(s) should be produced at which facility. To the best of our knowledge, until this study, there was no scientific approach about this problem at the firm and decisions were being given intuitively. In this study, some logistic cost parameters have been defined and with these parameters a mathematical model has been constructed. Defined and collected cost parameters are handling cost of parts, shipment cost of parts and shipment cost of welding fixtures. Constructed multi-objective mathematical model aims to minimize these costs while aims to balance the workload between two locations. Results showed that defined model can give optimum solutions in reasonable computing times. Also, this result gave encouragement to develop the model with addition of new logistic cost parameters.

Keywords: automotive subcontract, facility assignment, logistic costs, multi-objective models

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Authors: M. Yildirim, A. S. Kipcak, F. T. Senberber, M. O. Asensio, E. M. Derun, S. Piskin

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Potassium borates, which are widely used in welding and metal refining industry, as a lubricating oil additive, cement additive, fiberglass additive and insulation compound, are one of the important groups of borate minerals. In this study the production of a potassium borate mineral via hydrothermal method is aimed. The potassium source of potassium nitrate (KNO3) was used along with a sodium source of sodium hydroxide (NaOH) and boron source of boric acid (H3BO3). The constant parameters of reaction temperature and reaction time were determined as 80°C and 1 h, respectively. The molar ratios of 1:1:3 (as KNO3:NaOH:H3BO3), 1:1:4, 1:1:5, 1:1:6 and 1:1:7 were used. Following the synthesis the identifications of the produced products were conducted by X-Ray Diffraction (XRD) and Fourier Transform Infrared Spectroscopy (FT-IR). The results of the experiments and analysis showed in the ratio of 1:1:6, the Santite mineral with powder diffraction file number (pdf no.) of 01-072-1688, which is known as potassium pentaborate (KB5O8•4H2O) was synthesized as best.

Keywords: hydrothermal synthesis, potassium borate, potassium nitrate, santite

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Authors: Yusri Yusof, Kamran Latif

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Computer Numeric Control (CNC) machine has been widely used in the industries since its inception. Currently, in CNC technology has been used for various operations like milling, drilling, packing and welding etc. with the rapid growth in the manufacturing world the demand of flexibility in the CNC machines has rapidly increased. Previously, the commercial CNC failed to provide flexibility because its structure was of closed nature that does not provide access to the inner features of CNC. Also CNC’s operating ISO data interface model was found to be limited. Therefore, to overcome that problem, Open Architecture Control (OAC) technology and STEP-NC data interface model are introduced. At present the Personal Computer (PC) has been the best platform for the development of open-CNC systems. In this paper, both ISO data interface model interpretation, its verification and execution has been highlighted with the introduction of the new techniques. The proposed is composed of ISO data interpretation, 3D simulation and machine motion control modules. The system is tested on an old 3 axis CNC milling machine. The results are found to be satisfactory in performance. This implementation has successfully enabled sustainable manufacturing environment.

Keywords: CNC, ISO 6983, ISO 14649, LabVIEW, open architecture control, reconfigurable manufacturing systems, sustainable manufacturing, Soft-CNC

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Authors: Vitalis Okwuchukwu Opara

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The task of nation building primarily consist in welding together, diverse cultural groups into a united nation state, which develops a centripetal political culture that makes its people see themselves as members of one nation linked together by more reliable ties than the coercion offered by the state. Comparatively on the contrary, most countries in the world today are comprised of diverse nationalities, each with its unique set of norms and values, which often come into conflict with others. As such, the task of nation building is in uniting these diverse cultural groups into a united nation state and various human elements that make up its geopolitical zone. The most outstanding impediment to achieving this task is unemployment. Unemployment is like a peril against the nation building. Unemployment is an obstacle for growth of a nation. Often it is said that the wise see obstacles as stepping-stones to advance further. The pangs of unemployment impede nation building such that sometimes it takes very long time to do away with the problem. In recent times, there has been a revolutionary wind blowing across the world. This wind is bound to wake up nations leaders to sit up to their responsibility. Unemployment causes youth restiveness, brings leaders to their knees. It breeds problem. This work is intended to expose the pangs of unemployment and its impending peril to nation building.

Keywords: pangs, unemployment, obstacles, nation-building

Procedia PDF Downloads 334

Authors: Getachew Demeissie Ayalew, Yongtao Sun, Yang Yang

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The spiral welded pipe manufacturing industry requires strict production standards for automated grinders for welding seams. However, traditional grinding machines in this sector are insufficient due to a lack of quality control protocols and inconsistent performance. This research aims to improve the quality of spiral welded pipes by developing intelligent automated abrasive belt grinding equipment. The system has equipped with six degrees of freedom (6 DOF) KUKA KR360 industrial robots, enabling concurrent grinding operations on both internal and external welds. The grinding robot control system is designed with a PLC, and a human-machine interface (HMI) system is employed for operations. The system includes an electric speed controller, data connection card, DC driver, analog amplifier, and HMI for input data. This control system enables the grinding of spiral welded pipe. It ensures consistent production quality and cost-effectiveness by reducing the product life cycle and minimizing risks in the working environment.

Keywords: Intelligent Systems, Spiral Welded Pipe, Grinding, Industrial Robot, End-Effector, PLC Controller System, 3D Laser Sensor, HMI.

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Authors: J. Iwaro, A. Mwasha, K. Ramsubhag

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Global warming has become a threat of our time. It poses challenges to the existence of beings on earth, the built environment, natural environment and has made a clear impact on the level of energy and water consumption. As such, increase in the ambient temperature increases indoor and outdoor temperature level of the buildings which brings about the use of more energy and mechanical air conditioning systems. In addition, in view of the increased modernization and economic growth in the developing countries, a significant amount of energy is being used, especially those with hot climatic conditions. Since modernization in developing countries is rising rapidly, more pressure is being placed on the buildings and energy resources to satisfy the indoor comfort requirements. This paper presents a sustainable passive roof solution as a means of reducing energy cooling loads for satisfying human comfort requirements in a hot climate. As such, the study based on the field study data discusses indoor thermal roof design strategies for a hot climate by investigating the impacts of roof thermal performance on indoor thermal comfort in naturally ventilated building envelope small scaled structures. In this respect, the traditional concrete flat roof, corrugated galvanised iron roof and pre-painted standing seam roof were used. The experiment made used of three identical small scale physical models constructed and sited on the roof of a building at the University of the West Indies. The results show that the utilization of insulation in traditional roofing systems will significantly reduce heat transfer between the internal and ambient environment, thus reducing the energy demand of the structure and the relative carbon footprint of a structure per unit area over its lifetime. Also, the application of flat slab concrete roofing system showed the best performance as opposed to the metal roof sheeting alternative systems. In addition, it has been shown experimentally through this study that a sustainable passive roof solution such as insulated flat concrete roof in hot dry climate has a better cooling strength that can provide building occupant with a better thermal comfort, conducive indoor conditions and energy efficiency.

Keywords: building envelope, roof, energy consumption, thermal comfort

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Authors: Khaled Ayfi

Abstract:

In industrial oxygen systems at high temperature and high pressure, contamination by solid particles is one of the principal causes of ignition hazards. Indeed, gas can sweep away particles, generated by corrosion inside the pipes or during maintenance operations (welding residues, careless disassembly, etc.) and produce accumulations at places where the gas velocity decrease. Moreover, in such an environment rich in oxygen (oxidant), particles are highly reactive and can ignite system walls more actively and at higher temperatures. Oxidation based thermal effects are responsible for mechanical properties lost, leading to the destruction of the pressure equipment wall. To deal with this problem, a numerical analysis is done regarding a sample representative of a wall subjected to pressure and temperature. The validation and analysis are done comparing the numerical simulations results to experimental measurements. More precisely, in this work, we propose a numerical model that describes the thermomechanical behavior of thin metal disks under pressure and subjected to laser heating. This model takes into account the geometric and material nonlinearity and has been validated by the comparison of simulation results with experimental measurements.

Keywords: ignition, oxygen, numerical simulation, thermomechanical behavior

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Authors: Khalil Aryanfar, Pariya Gholipor, Elmira Hafez

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This study examines the proportionality between the needs of industry and technical and vocational training of male and female vocational schools. The research method was descriptive that was conducted in two parts: documentary analysis and needs assessment and Delphi method was used in the need assessment. The statistical population of the study included 312 individuals from the industry sector employers and 52 of them were selected through stratified random sampling. Methods of data collection in this study, upstream documents include: document of the development of technical and vocational training, Statistical Yearbook 1393 in Tehran, the available documents in Isfahan Planning Department, the findings indicate that there is an almost proportionality between the needs of industry and Vocational training of male and female vocational schools in fields of welding, industrial electronics, electro technique, industrial drawing, auto mechanics, design, packaging, machine tool, metalworking, construction, accounting, computer graphics and the Administrative Affairs. The findings indicate that there is no proportionality between the needs of industry and Vocational training of male and female vocational schools in fields of Thermal - cooling systems, building electricity, building drawing, interior architecture, car electricity and motor repair.

Keywords: needs assessment, technical and vocational training, industry

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Authors: S. Talebnezhad, S. Pourmahdian, D. Soudbar, M. Khosravani, J. Merasi

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Adding toughened polypropylene and plastomer in FFS 3 layered blown film formulation resulted in superior dart impact and MD tear resistance along with acceptable tensile properties in TD and MD. The optimum loading of toughened polypropylene and plastomer in each layer depends on miscibility of polypropylene in polyethylene medium, mechanical properties, welding characteristics in bags top and bottoms and friction coefficient of film surfaces. Film property tests and efficiency of FFS machinery during processing in industrial scale showed that about 4% loading of plastomer and 16% of toughened polypropylene (reactor grade) in middle layer and loading of 0-1% plastomer and 5-19% of toughened polypropylene in other layers results optimum characteristics in the formulation based on 1-butene LLDPE grade with MFR of 0.9 and LDPE grade with MFI of 0.3. Both the plastomer and toughened polypropylene had the MFI of blow 1 and the TiO2 and processing aid masterbatches loading was 2%. The friction coefficient test results also represented the anti-block masterbatch could be omitted from formulation with adding toughened polypropylene due to partial miscibility of PP in PE which makes the surface of films somewhat bristly.

Keywords: FFS 3 layered blown film, toughened polypropylene, plastomer, dart impact, tear resistance

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Authors: S. S. Amoor

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Insecurity is becoming a major tool in the hand of Nigeria’s enemies to increase poverty and hatred among the citizens and split the county into several political segments. It is based on this background that this paper critically examines Vocational and Technical Education as a practical and realistic approach to reducing insecurity in Nigeria so as to save the country from total disintegration. The paper discusses the concept of insecurity, types, causes and effects of insecurity, and how vocational and technical education and its variables are fundamental and practical measures to reducing insecurity in Nigeria. The paper concludes that the large army of unemployed and unskilled youths in Nigeria requires immediate attention in the area of provision of marketable vocational and technical skills, creativity and competences that will prepare them for employment or self-reliance. It is hoped that government jobs or self-employment will keep the teeming youths busy and therefore take their minds away from odd jobs that threaten the security of the country. In line with these, the paper recommends, among others, that since the teeming unemployed and unskilled youths are mostly from the rural areas, the state governments in collaboration with the local governments should take appropriate steps to provide the youths with vocational skills in carpentry, fashion designing, hair-dressing, driving, welding, mechanical works, among others. Once the youths are involved in one skilled trade or the other, insecurity would be reduced.

Keywords: vocational and technical education, insecurity, practical approach to reducing insecurity, unemployment

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Authors: Badr Alsulami, Ahmed S. Elamary

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This paper summarizes and presents main results of an in-depth numerical analysis dealing with the shear buckling resistance of aluminum plate girders. The studies conducted have permitted the development of a simple design expression to determine the critical shear buckling stress in aluminum web panels. This expression takes into account the effects of reduction of strength in aluminum alloys due to the welding process. Ultimate shear resistance (USR) of plate girders can be obtained theoretically using Cardiff theory or Hӧglund’s theory. USR of aluminum alloy plate girders predicted theoretically using BS8118 appear inconsistent when compared with test data. Theoretical predictions based on Hӧglund’s theory, are more realistic. Cardiff theory proposed to predict the USR of steel plate girders only. Welded aluminum alloy plate girders studied experimentally by others; the USR resulted from tests are reviewed. Comparison between the test results with the values obtained from Hӧglund’s theory, BS8118 design method, and Cardiff theory performed theoretically. Finally, a new equation based on Cardiff tension-field theory proposed to predict theoretically the USR of aluminum plate girders.

Keywords: shear resistance, aluminum, Cardiff theory, Hӧglund's theory, plate girder

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Authors: Jeffrey Cacho, Sherwin Reyes

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The research targeted enhancing energy utilization and reducing waste in roasting processes, particularly in Camarines Norte, where Bounty Agro Ventures Incorporated dominates through brands such as Chooks-to-Go, Uling Roaster, and Reyal. Competitors like Andok’s and Baliwag Lechon Manok also share the market. A staggering 90% of these businesses use traditional glass-type roasting furnaces fueled by wood charcoal, leading to significant energy loss and inefficiency due to suboptimal heat conservation. Only a mere 10% employ electric ovens. Many available furnaces, typically constructed from industrial materials through welding and other metal joining techniques, are not energy-efficient. Cost-prohibitive commercial options compel some micro-enterprises to fabricate their furnaces. The study proposed developing an eco-friendly, cost-effective roasting furnace with excellent heat retention. The distinct design aimed to reduce cooks' heat exposure and overall fuel consumption. The furnace features an angle bar frame, a combustion chute for fuel burning, a heat-retaining clay-walled chamber, and a top cover, all contributing to improved energy savings and user safety.

Keywords: biomass roasting furnace, heat storage, combustion chute, start-up roasting business

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Authors: Stephen J Futter, Michael I Okereke

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This paper presents an investigation of the premature in-service failure of the engine mounting towers that form part of the bedframe commonly used for industrial power generation applications. The client during a routine in-service assessment of the generator set observed that the engine mounting towers had cracked. Thus, this study has investigated in detail the origin of the crack and proffered solutions to prevent a re-occurrence. Seven step problem solving methodology was followed during this paper. The study used both experimental and numerical approaches to understand, monitor and evaluate the cause and evolution of the premature failure. Findings from this study indicated that the failure resulted from a combination of varied processes from procurement of material parts, material selection, welding processes and inaptly designed load-bearing mechanics of the generating set and its mounting arrangement. These in-field observations and experimental simulations provided insights to design and validate a numerical finite element sub-model of the cracked bedframe considering thermal cycling: designed as part of these investigations. Resulting findings led to a recommendation of several procedural changes that should be adopted by the manufacturer, in order to prevent the re-occurrence of such pre-mature failure in future industrial applications.

Keywords: Engine, Premature Failure, Failure Analysis, Finite Element Model

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Authors: Balamurali Gunji, B. B. V. L. Deepak, B. B. Biswal, Amrutha Rout, Golak Bihari Mohanta

Abstract:

Robots play an important role in the operations like pick and place, assembly, spot welding and much more in manufacturing industries. Out of those, assembly is a very important process in manufacturing, where 20% of manufacturing cost is wholly occupied by the assembly process. To do the assembly task effectively, Assembly Sequences Planning (ASP) is required. ASP is one of the multi-objective non-deterministic optimization problems, achieving the optimal assembly sequence involves huge search space and highly complex in nature. Many researchers have followed different algorithms to solve ASP problem, which they have several limitations like the local optimal solution, huge search space, and execution time is more, complexity in applying the algorithm, etc. By keeping the above limitations in mind, in this paper, a new automated optimal robotic assembly sequence planning using Artificial Bee Colony (ABC) Algorithm is proposed. In this algorithm, automatic extraction of assembly predicates is done using Computer Aided Design (CAD) interface instead of extracting the assembly predicates manually. Due to this, the time of extraction of assembly predicates to obtain the feasible assembly sequence is reduced. The fitness evaluation of the obtained feasible sequence is carried out using ABC algorithm to generate the optimal assembly sequence. The proposed methodology is applied to different industrial products and compared the results with past literature.

Keywords: assembly sequence planning, CAD, artificial Bee colony algorithm, assembly predicates

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Authors: Junwon Seo, Bipin Adhikari, Euiseok Jeong

Abstract:

This paper is intended to evaluate the structural performance of welded electronic road signs under various damage scenarios (DSs) using a finite element (FE) model calibrated with full-scale ultimate load testing results. The tested electronic road sign specimen was built with a back skin made of 5052 aluminum and two channels and a frame made of 6061 aluminum, where the back skin was connected to the frame by welding. The size of the tested specimen was 1.52 m long, 1.43 m wide, and 0.28 m deep. An actuator applied vertical loads at the center of the back skin of the specimen, resulting in a displacement of 158.7 mm and an ultimate load of 153.46 kN. Using these testing data, generation and calibration of a FE model of the tested specimen were executed in ABAQUS, indicating that the difference in the ultimate load between the calibrated model simulation and full-scale testing was only 3.32%. Then, six different DSs were simulated where the areas of the welded connection in the calibrated model were diminished for the DSs. It was found that the corners at the back skin-frame joint were prone to connection failure for all the DSs, and failure of the back skin-frame connection occurred remarkably from the distant edges.

Keywords: computational analysis, damage scenarios, electronic road signs, finite element, welded connections

Procedia PDF Downloads 65