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Authors: Tomasz Dubiel, Tadeusz Balawender, Mirosław Osetek

Abstract:

The paper presents the influence of non-metallic inclusions on the multi-stage forging process and the mechanical properties of the dodecagon socket bolt used in the automotive industry. The detected metallurgical defect was so large that it directly influenced the mechanical properties of the bolt and resulted in failure to meet the requirements of the mechanical property class. In order to assess the defect, an X-ray examination and metallographic examination of the defective bolt were performed, showing exogenous non-metallic inclusion. The size of the defect on the cross section was 0.531 mm in width and 1.523 mm in length; the defect was continuous along the entire axis of the bolt. In analysis, a finite element method (FEM) simulation of the multi-stage forging process was designed, taking into account a non-metallic inclusion parallel to the sample axis, reflecting the studied case. The process of defect propagation due to material upset in the head area was analyzed. The final forging stage in shaping the dodecagonal socket and filling the flange area was particularly studied. The effect of the defect was observed to significantly reduce the effective cross-section as a result of the expansion of the defect perpendicular to the axis of the bolt. The mechanical properties of products with and without the defect were analyzed. In the first step, the hardness test confirmed that the required value for the mechanical class 8.8 of both bolt types was obtained. In the second step, the bolts were subjected to a static tensile test. The bolts without the defect gave a positive result, while all 10 bolts with the defect gave a negative result, achieving a tensile strength below the requirements. Tensile strength tests were confirmed by metallographic tests and FEM simulation with perpendicular inclusion spread in the area of the head. The bolts were damaged directly under the bolt head, which is inconsistent with the requirements of ISO 898-1. It has been shown that non-metallic inclusions with orientation in accordance with the axis of the bolt can directly cause loss of functionality and these defects should be detected even before assembling in the machine element.

Keywords: continuous casting, multi-stage forging, non-metallic inclusion, upset bolt head

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Authors: H. M. Nanjundaswamy, S. K. Nath, S. Ray

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TiO₂ particles have been added in molten aluminium to result in aluminium based cast Al/Al₃Ti-Al₂O₃ composite, which has been added then to molten magnesium to synthesize magnesium based cast Mg-Al/Al₃Ti-Al₂O₃ composite. The nominal compositions in terms of Mg, Al, and TiO₂ contents in the magnesium based composites are Mg-9Al-0.6TiO₂, Mg-9Al-0.8TiO₂, Mg-9Al-1.0TiO₂ and Mg-9Al-1.2TiO₂ designated respectively as MA6T, MA8T, MA10T and MA12T. The microstructure of the cast magnesium based composite shows grayish rods of intermetallics Al₃Ti, inherited from aluminium based composite but these rods, on hot forging, breaks into smaller lengths decreasing the average aspect ratio (length to diameter) from 7.5 to 3.0. There are also cavities in between the broken segments of rods. β-phase in cast microstructure, Mg₁₇Al₁₂, dissolves during heating prior to forging and re-precipitates as relatively finer particles on cooling. The amount of β-phase also decreases on forging as segregation is removed. In both the cast and forged composite, the Brinell hardness increases rapidly with increasing addition of TiO₂ but the hardness is higher in forged composites by about 80 BHN. With addition of higher level of TiO₂ in magnesium based cast composite, yield strength decreases progressively but there is marginal increase in yield strength over that of the cast Mg-9 wt. pct. Al, designated as MA alloy. But the ultimate tensile strength (UTS) in the cast composites decreases with the increasing particle content indicating possibly an early initiation of crack in the brittle inter-dendritic region and their easy propagation through the interfaces of the particles. In forged composites, there is a significant improvement in both yield strength and UTS with increasing TiO₂ addition and also, over those observed in their cast counterpart, but at higher addition it decreases. It may also be noted that as in forged MA alloy, incomplete recovery of forging strain increases the strength of the matrix in the composites and the ductility decreases both in the forged alloy and the composites. Initiation fracture toughness, J_IC, decreases drastically in cast composites compared to that in MA alloy due to the presence of intermetallic Al₃Ti and Al₂O₃ particles in the composite. There is drastic reduction of J_IC on forging both in the alloy and the composites, possibly due to incomplete recovery of forging strain in both as well as breaking of Al₃Ti rods and the voids between the broken segments of Al₃Ti rods in composites. The ratio of tearing modulus to elastic modulus in cast composites show higher ratio, which increases with the increasing TiO₂ addition. The ratio decreases comparatively more on forging of cast MA alloy than those in forged composites.

Keywords: Composite, fracture toughness, forging, tensile properties.

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Authors: A. M. Alaskari, S. E. Oraby

Abstract:

The quality of a machined surface is becoming more and more important to justify the increasing demands of sophisticated component performance, longevity, and reliability. Usually, any machining operation leaves its own characteristic evidence on the machined surface in the form of finely spaced micro irregularities (surface roughness) left by the associated indeterministic characteristics of the different elements of the system: tool-machineworkpart- cutting parameters. However, one of the most influential sources in machining affecting surface roughness is the instantaneous state of tool edge. The main objective of the current work is to relate the in-process immeasurable cutting edge deformation and surface roughness to a more reliable easy-to-measure force signals using a robust non-linear time-dependent modeling regression techniques. Time-dependent modeling is beneficial when modern machining systems, such as adaptive control techniques are considered, where the state of the machined surface and the health of the cutting edge are monitored, assessed and controlled online using realtime information provided by the variability encountered in the measured force signals. Correlation between wear propagation and roughness variation is developed throughout the different edge lifetimes. The surface roughness is further evaluated in the light of the variation in both the static and the dynamic force signals. Consistent correlation is found between surface roughness variation and tool wear progress within its initial and constant regions. At the first few seconds of cutting, expected and well known trend of the effect of the cutting parameters is observed. Surface roughness is positively influenced by the level of the feed rate and negatively by the cutting speed. As cutting continues, roughness is affected, to different extents, by the rather localized wear modes either on the tool nose or on its flank areas. Moreover, it seems that roughness varies as wear attitude transfers from one mode to another and, in general, it is shown that it is improved as wear increases but with possible corresponding workpart dimensional inaccuracy. The dynamic force signals are found reasonably sensitive to simulate either the progressive or the random modes of tool edge deformation. While the frictional force components, feeding and radial, are found informative regarding progressive wear modes, the vertical (power) components is found more representative carrier to system instability resulting from the edge-s random deformation.

Keywords: Dynamic force signals, surface roughness (finish), tool wear and deformation, tool wear modes (nose, flank)

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Authors: Siddhartha Bhattacharyya, Paramartha Dutta, Ujjwal Maulik, Prashanta Kumar Nandi

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A multilayer self organizing neural neural network (MLSONN) architecture for binary object extraction, guided by a beta activation function and characterized by backpropagation of errors estimated from the linear indices of fuzziness of the network output states, is discussed. Since the MLSONN architecture is designed to operate in a single point fixed/uniform thresholding scenario, it does not take into cognizance the heterogeneity of image information in the extraction process. The performance of the MLSONN architecture with representative values of the threshold parameters of the beta activation function employed is also studied. A three layer bidirectional self organizing neural network (BDSONN) architecture comprising fully connected neurons, for the extraction of objects from a noisy background and capable of incorporating the underlying image context heterogeneity through variable and adaptive thresholding, is proposed in this article. The input layer of the network architecture represents the fuzzy membership information of the image scene to be extracted. The second layer (the intermediate layer) and the final layer (the output layer) of the network architecture deal with the self supervised object extraction task by bi-directional propagation of the network states. Each layer except the output layer is connected to the next layer following a neighborhood based topology. The output layer neurons are in turn, connected to the intermediate layer following similar topology, thus forming a counter-propagating architecture with the intermediate layer. The novelty of the proposed architecture is that the assignment/updating of the inter-layer connection weights are done using the relative fuzzy membership values at the constituent neurons in the different network layers. Another interesting feature of the network lies in the fact that the processing capabilities of the intermediate and the output layer neurons are guided by a beta activation function, which uses image context sensitive adaptive thresholding arising out of the fuzzy cardinality estimates of the different network neighborhood fuzzy subsets, rather than resorting to fixed and single point thresholding. An application of the proposed architecture for object extraction is demonstrated using a synthetic and a real life image. The extraction efficiency of the proposed network architecture is evaluated by a proposed system transfer index characteristic of the network.

Keywords: Beta activation function, fuzzy cardinality, multilayer self organizing neural network, object extraction,

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Authors: Aliya Isaeva, Anar Sultaniarova

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The report focuses on such an important indicator of the nature and direction of development of ethnic and cultural processes in the Republic of Kazakhstan, as ethno linguistic situation. It is shown that, in essence, on the one hand, expresses the degree of the actual propagation and the level of use of the languages of the various ethnic communities. On the other hand, reflects the important patterns, trends and prospects of ethno-cultural and ethnodemographic processes in the Republic. It is important to note that the ethno linguistic situation in different regions of Kazakhstan, due to its more dynamic and much more difficult to demonstrate a much greater variety of options when compared with the ethnic situation in the country. For the two major ethnic groups of the republic – Kazakh and Russian language ethno differentiating retains its value, while for the other ethnic groups observed decline in the importance of this indicator. As you know, the language of international communication in the country is Russian. As the censuses of population, the Russian language in many areas of Northern, Central and Eastern Kazakhstan becomes a means of ethno linguistic development for most of the non-Russian population. This is most clearly illustrated by the Germans, and the Slavic ethnic groups. In this case, the Russian language is not just a means of international communication for a number of ethnic groups, and ethnic groups, it becomes a factor of ethnic self-expression. The value of the Kazakh language as their mother tongue for the other groups of the population is small. More clearly it can be traced only to the Turkic-speaking population of the republic – Uzbeks, Uighurs, Tatars, Turks, etc. The state Kazakh language is a means of international communication in the Western and Southern Kazakhstan, with a predominance of the Kazakh population. The report shows that the most important factor in the development of ethno-linguistic and ethno-cultural processes is bilingualism. Comparative analysis of materials census shows, first, on the increase of the proportion of bilingual population among Kazakhs and Russian, and second, to reduce the proportion of bilingual population of other ethnic groups living in Kazakhstan, and third, a higher proportion bilingual population among residents than rural residents, regardless of their ethnicity. Bilingualism is mainly of a "national Kazakh", "national Russian" or "Kazakh-national" or "Russian-national" character. The President N.A. Nazarbayev said that the Kazakh language is the most important factor in the consolidation of the people of Kazakhstan. He therefore called on government and other state and local representative bodies fully develop the state language, to create all the necessary organizational, material and technical conditions for free and open learning the state language by all citizens of the Republic of Kazakhstan.

Keywords: Ethnos, ethno cultural processes, ethnolinguistic situation, mother tongue, bilingualism.

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Authors: S. Mehrab Amiri, Nasser Talebbeydokhti

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Modeling sediment transport processes by means of numerical approach often poses severe challenges. In this way, a number of techniques have been suggested to solve flow and sediment equations in decoupled, semi-coupled or fully coupled forms. Furthermore, in order to capture flow discontinuities, a number of techniques, like artificial viscosity and shock fitting, have been proposed for solving these equations which are mostly required careful calibration processes. In this research, a numerical scheme for solving shallow water and Exner equations in fully coupled form is presented. First-Order Centered scheme is applied for producing required numerical fluxes and the reconstruction process is carried out toward using Monotonic Upstream Scheme for Conservation Laws to achieve a high order scheme.  In order to satisfy C-property of the scheme in presence of bed topography, Surface Gradient Method is proposed. Combining the presented scheme with fourth order Runge-Kutta algorithm for time integration yields a competent numerical scheme. In addition, to handle non-prismatic channels problems, Cartesian Cut Cell Method is employed. A trained Multi-Layer Perceptron Artificial Neural Network which is of Feed Forward Back Propagation (FFBP) type estimates sediment flow discharge in the model rather than usual empirical formulas. Hydrodynamic part of the model is tested for showing its capability in simulation of flow discontinuities, transcritical flows, wetting/drying conditions and non-prismatic channel flows. In this end, dam-break flow onto a locally non-prismatic converging-diverging channel with initially dry bed conditions is modeled. The morphodynamic part of the model is verified simulating dam break on a dry movable bed and bed level variations in an alluvial junction. The results show that the model is capable in capturing the flow discontinuities, solving wetting/drying problems even in non-prismatic channels and presenting proper results for movable bed situations. It can also be deducted that applying Artificial Neural Network, instead of common empirical formulas for estimating sediment flow discharge, leads to more accurate results.

Keywords: Artificial neural network, morphodynamic model, sediment continuity equation, shallow water equations.

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Authors: T. Garlan, I. Gabelotaud, S. Lucas, E. Marchès

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Production of a global sedimentological seabed map has been initiated in 1995 to provide the necessary tool for searches of aircraft and boats lost at sea, to give sedimentary information for nautical charts, and to provide input data for acoustic propagation modelling. This original approach had already been initiated one century ago when the French hydrographic service and the University of Nancy had produced maps of the distribution of marine sediments of the French coasts and then sediment maps of the continental shelves of Europe and North America. The current map of the sediment of oceans presented was initiated with a UNESCO's general map of the deep ocean floor. This map was adapted using a unique sediment classification to present all types of sediments: from beaches to the deep seabed and from glacial deposits to tropical sediments. In order to allow good visualization and to be adapted to the different applications, only the granularity of sediments is represented. The published seabed maps are studied, if they present an interest, the nature of the seabed is extracted from them, the sediment classification is transcribed and the resulted map is integrated in the world map. Data come also from interpretations of Multibeam Echo Sounder (MES) imagery of large hydrographic surveys of deep-ocean. These allow a very high-quality mapping of areas that until then were represented as homogeneous. The third and principal source of data comes from the integration of regional maps produced specifically for this project. These regional maps are carried out using all the bathymetric and sedimentary data of a region. This step makes it possible to produce a regional synthesis map, with the realization of generalizations in the case of over-precise data. 86 regional maps of the Atlantic Ocean, the Mediterranean Sea, and the Indian Ocean have been produced and integrated into the world sedimentary map. This work is permanent and permits a digital version every two years, with the integration of some new maps. This article describes the choices made in terms of sediment classification, the scale of source data and the zonation of the variability of the quality. This map is the final step in a system comprising the Shom Sedimentary Database, enriched by more than one million punctual and surface items of data, and four series of coastal seabed maps at 1:10,000, 1:50,000, 1:200,000 and 1:1,000,000. This step by step approach makes it possible to take into account the progresses in knowledge made in the field of seabed characterization during the last decades. Thus, the arrival of new classification systems for seafloor has improved the recent seabed maps, and the compilation of these new maps with those previously published allows a gradual enrichment of the world sedimentary map. But there is still a lot of work to enhance some regions, which are still based on data acquired more than half a century ago.

Keywords: Marine sedimentology, seabed map, sediment classification, World Ocean.

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