Search results for: aluminothermic rail welding

Authors: Souvik Das, Janak Lal, Arthita Dey, Goutam Mukhopadhyay, Sandip Bhattacharya

Abstract:

Telescopic Front Fork (TFF) used in two wheelers, mainly motorcycle, is made from high strength steel, and is manufactured by high frequency induction welding process wherein hot rolled and pickled coils are used as input raw material for rolling of hollow tubes followed by heat treatment, surface treatment, cold drawing, tempering, etc. The final application demands superior quality TFF tubes w.r.t. surface finish and dimensional tolerances. This paper presents the investigation of two different types of failure of fork during operation. The investigation consists of visual inspection, chemical analysis, characterization of microstructure, and energy dispersive spectroscopy. In this paper, comprehensive investigations of two failed tube samples were investigated. In case of Sample #1, the result revealed that there was a pre-existing crack, known as hook crack, which leads to the cracking of the tube. Metallographic examination exhibited that during field operation the pre-existing hook crack was surfaced out leading to crack in the pipe. In case of Sample #2, presence of internal oxidation with decarburised grains inside the material indicates origin of the defect from slab stage.

Keywords: Telescopic front fork, induction welding, hook crack, internal oxidation.

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Authors: M. Magrini, D. Moroni, G. Palazzese, G. Pieri, D. Azzarelli, A. Spada, L. Fanucci, O. Salvetti

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Railway crossings are complex entities whose optimal management cannot be addressed unless with the help of an intelligent transportation system integrating information both on train and vehicular flows. In this paper, we propose an integrated system named SIMPLE (Railway Safety and Infrastructure for Mobility applied at level crossings) that, while providing unparalleled safety in railway level crossings, collects data on rail and road traffic and provides value-added services to citizens and commuters. Such services include for example alerts, via variable message signs to drivers and suggestions for alternative routes, towards a more sustainable, eco-friendly and efficient urban mobility. To achieve these goals, SIMPLE is organized as a System of Systems (SoS), with a modular architecture whose components range from specially-designed radar sensors for obstacle detection to smart ETSI M2M-compliant camera networks for urban traffic monitoring. Computational unit for performing forecast according to adaptive models of train and vehicular traffic are also included. The proposed system has been tested and validated during an extensive trial held in the mid-sized Italian town of Montecatini, a paradigmatic case where the rail network is inextricably linked with the fabric of the city. Results of the tests are reported and discussed.

Keywords: Intelligent Transportation Systems (ITS), railway, railroad crossing, smart camera networks, radar obstacle detection, real-time traffic optimization, IoT, ETSI M2M, transport safety.

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Authors: Sang Hwan Bak, Min Jung Kim, Dong Bok Lee

Abstract:

Fe-2%Mn-0.5%Si-0.2C steel was welded and corroded at 600, 700 and 800oC for 20 h in 1 atm of N2/H2S/H2O-mixed gas in order to characterize the high-temperature corrosion behavior of the welded joint. Corrosion proceeded fast and almost linearly. It increased with an increase in the corrosion temperature. H2S formed FeS owing to sulfur released from H2S. The scales were fragile and nonadherent.

Keywords: Fe-Mn-Si Steel, Corrosion, Welding, Sulfidation, H2S Gas.

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Authors: S. Shakibaei, P. Alpkokin

Abstract:

The railway network is one of the major components of a transportation system in a country which may be an indicator of the country’s level of economic improvement. Since 2000s on, revival of national railways and development of High Speed Rail (HSR) lines are one of the most remarkable policies of Turkish government in railway sector. Within this trend, the railway age is to be revived and coming decades will be a golden opportunity. Indubitably, major infrastructures such as road and railway networks require sizeable investment capital, precise maintenance and reparation. Traditionally, governments are held responsible for funding, operating and maintaining these infrastructures. However, lack or shortage of financial resources, risk responsibilities (particularly cost and time overrun), and in some cases inefficacy in constructional, operational and management phases persuade governments to find alternative options. Financial power, efficient experiences and background of private sector are the factors convincing the governments to make a collaboration with private parties to develop infrastructures. Public-Private Partnerships (PPP or 3P or P3) and related regulatory issues are born considering these collaborations. In Turkey, PPP approaches have attracted attention particularly during last decade and these types of investments have been accelerated by government to overcome budget limitations and cope with inefficacy of public sector in improving transportation network and its operation. This study mainly tends to present a comprehensive overview of PPP concept, evaluate the regulatory procedure in Europe and propose a general framework for Turkish State Railways (TCDD) as an outlook on privatization, liberalization and deregulation of railway network.

Keywords: Deregulation, high-speed rail, liberalization, privatization, public-private partnership.

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Authors: Masoud Mohammadpour, Blair Carlson, Radovan Kovacevic

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The quality of laser welded-brazed (LWB) joints were strongly dependent on the main process parameters, therefore the effect of laser power (3.2–4 kW), welding speed (60–80 mm/s) and wire feed rate (70–90 mm/s) on mechanical strength and surface roughness were investigated in this study. The comprehensive optimization process by means of response surface methodology (RSM) and desirability function was used for multi-criteria optimization. The experiments were planned based on Box– Behnken design implementing linear and quadratic polynomial equations for predicting the desired output properties. Finally, validation experiments were conducted on an optimized process condition which exhibited good agreement between the predicted and experimental results. AlSi3Mn1 was selected as the filler material for joining aluminum alloy 6022 and hot-dip galvanized steel in coach peel configuration. The high scanning speed could control the thickness of IMC as thin as 5 µm. The thermal simulations of joining process were conducted by the Finite Element Method (FEM), and results were validated through experimental data. The Fe/Al interfacial thermal history evidenced that the duration of critical temperature range (700–900 °C) in this high scanning speed process was less than 1 s. This short interaction time leads to the formation of reaction-control IMC layer instead of diffusion-control mechanisms.

Keywords: Laser welding-brazing, finite element, response surface methodology, multi-response optimization, cross-beam laser.

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Authors: Xiaohui Han, Yuhan Wang, Jing Shi

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This paper proposed a stiffness analysis method for a 3-PRS mechanism for welding thick aluminum plate using FSW technology. In the molding process, elastic deformation of lead-screws and links are taken into account. This method is based on the virtual work principle. Through a survey of the commonly used stiffness performance indices, the minimum and maximum eigenvalues of the stiffness matrix are used to evaluate the stiffness of the 3-PRS mechanism. Furthermore, A FEA model has been constructed to verify the method. Finally, we redefined the workspace using the stiffness analysis method.

Keywords: 3-PRS, parallel mechanism, stiffness analysis, workspace.

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Authors: Suparna Karmakar, Ranjan Dasgupta

Abstract:

Railway Stations are prone to emergency due to various reasons and proper monitor of railway stations are of immense importance from various angles. A Petri-net representation of a web-service-based Emergency management system has been proposed in this paper which will help in monitoring situation of train, track, signal etc. and in case of any emergency, necessary resources can be dispatched.

Keywords: Business process, Petri net, Rail Station Emergency Management, Web service based system

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Authors: Madjid Meriem-Benziane, Hamou Zahloul

Abstract:

The demand of hydrocarbons has increased the construction of pipelines and the protection of the physical and mechanical integrity of the already existing infrastructure. Corrosion is the main reason of failures in the pipeline and it is mostly produced by acid (HCOOCH3). In this basis, a CFD code was used, in order to study the corrosion of internal wall of hydrocarbons pipeline. In this situation, the corrosion phenomenon shows a growing deposit, which causes defect damages (welding or fabrication) at diverse positions along the pipeline. The solution of the pipeline corrosion is based on the diminution of the Naphthenic acid.

Keywords: Pipeline, corrosion, Naphthenic acid (NA), CFD.

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Authors: Ali Göksenli, Barlas Eryürek

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In this study, failure analysis of pipe system at a micro hydroelectric power plant is investigated. Failure occurred at the pipe system in the powerhouse during shut down operation of the water flow by a valve. This locking had caused a sudden shock wave, also called “Water-hammer effect”, resulting in noise and inside pressure increase. After visual investigation of the effect of the shock wave on the system, a circumference crack was observed at the pipe flange weld region. To establish the reason for crack formation, calculations of pressure and stress values at pipe, flange and welding seams were carried out and concluded that safety factor was high (2.2), indicating that no faulty design existed. By further analysis, pipe system and hydroelectric power plant was examined. After observations it is determined that the plant did not include a ventilation nozzle (air trap), that prevents the system of sudden pressure increase inside the pipes which is caused by water-hammer effect. Analyses were carried out to identify the influence of water-hammer effect on inside pressure increase and it was concluded that, according Jowkowsky’s equation, shut down time is effective on inside pressure increase. The valve closing time was uncertain but by a shut down time of even one minute, inside pressure would increase by 7.6 bar (working pressure was 34.6 bar). Detailed investigations were also carried out on the assembly of the pipe-flange system by considering technical drawings. It was concluded that the pipe-flange system was not installed according to the instructions. Two of five weld seams were not applied and one weld was carried out faulty. This incorrect and inadequate weld seams resulted in; insufficient connection of the pipe to the flange constituting a strong notch effect at weld seam regions, increase in stress values and the decrease of strength and safety factor.

Keywords: Failure analysis, hydroelectric plant, water-hammer, crack, welding seam.

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Authors: Polo G. Yohn Edison, Rocha F. Pedricto

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This work presents a study about a retaining structure designed for the duplication of the rail FEPASA on the 74th km between Santos and São Paulo. This structure, an anchored retaining wall, was instrumented in the anchors heads with strain gauges in order to monitor its loads. The load measurements occurred during the performance test, locking and also after the works were concluded. A decrease on anchors loads is noticed at the moment immediately after the locking, during construction and after the works finished. It was observed that a loss of load in the anchors occurred to a maximum of 54%.

Keywords: Anchors, Instrumentation, Retaining wall, Strain gauges.

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Authors: S. Gómez, G. Sánchez, J. Zarama, M. Castañeda Ramos, J. Escoto Alcántar, J. Torres, A. Núñez, S. Santana, F. Nájera, J. A. Lopez

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This paper shows in detail the mathematical model of direct and inverse kinematics for a robot manipulator (welding type) with four degrees of freedom. Using the D-H parameters, screw theory, numerical, geometric and interpolation methods, the theoretical and practical values of the position of robot were determined using an optimized algorithm for inverse kinematics obtaining the values of the particular joints in order to determine the virtual paths in a relatively short time.

Keywords: Kinematics, degree of freedom, optimization, robot manipulator.

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Authors: H. Pasternak, A. Chwastek

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The paper describes the results from a research project about repair of welds. The repair was carried out by grinding the flawed seams and re-welding them. The main task was to determine the FAT classes of original state and after repair of seams according to the assessment procedures, such as nominal, structural and effective notch stress approach. The first part shows the results of the tests, the second part encloses numerical analysis and evaluation of results to determine the fatigue strength classes according to three assessment procedures.

Keywords: Cyclic loading, fatigue crack, post-weld treatment, seams’ repair.

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Authors: F. Fekak, A. Gravouil, M. Brun, B. Depale

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During an earthquake, a bridge crane may be subjected to multiple impacts between crane wheels and rail. In order to model such phenomena, a time-history dynamic analysis with a multi-scale approach is performed. The high frequency aspect of the impacts between wheels and rails is taken into account by a Lagrange explicit event-capturing algorithm based on a velocity-impulse formulation to resolve contacts and impacts. An implicit temporal scheme is used for the rest of the structure. The numerical coupling between the implicit and the explicit schemes is achieved with a heterogeneous asynchronous time-integrator.

Keywords: Earthquake, bridge crane, heterogeneous asynchronous time-integrator, impacts.

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Authors: Chang-Hung Hsu, Chun-Yao Lee, Guan-Lin Liao, Yung-Tsan Jou, Jin-Maun Ho, Yu-Hua Hsieh, Yi-Xing Shen

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This article simulates the wind generator set which has two fault bearing collar rail destruction and the gear box oil leak fault. The electric current signal which produced by the generator, We use Empirical Mode Decomposition (EMD) as well as Fast Fourier Transform (FFT) obtains the frequency range-s signal figure and characteristic value. The last step is use a kind of Artificial Neural Network (ANN) classifies which determination fault signal's type and reason. The ANN purpose of the automatic identification wind generator set fault..

Keywords: Wind-driven generator, Fast Fourier Transform, Neural network

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Authors: M. Centra

Abstract:

Due to the liberalization of countless electricity markets, load forecasting has become crucial to all public utilities for which electricity is a strategic variable. With the goal of contributing to the forecasting process inside public utilities, this paper addresses the issue of applying the Holt-Winters exponential smoothing technique and the time series analysis for forecasting the hourly electricity load curve of the Italian railways. The results of the analysis confirm the accuracy of the two models and therefore the relevance of forecasting inside public utilities.

Keywords: ARIMA models, Exponential smoothing, Electricity, Load forecasting, Rail transportation.

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Authors: Tooraj Hakim Elahi, Abdolamir Nekoubin

Abstract:

In many applications, magnetic suspension systems are required to operate over large variations in air gap. As a result, the nonlinearities inherent in most types of suspensions have a significant impact on performance. Specifically, it may be difficult to design a linear controller which gives satisfactory performance, stability, and disturbance rejection over a wide range of operating points. in this paper an optimal controller based on discontinuous mathematical model of the system for an electromagnetic suspension system which is applied in magnetic trains has been designed . Simulations show that the new controller can adapt well to the variance of suspension mass and gap, and keep its dynamic performance, thus it is superior to the classic controller.

Keywords: Magnetic Levitation, optimal controller, mass and gap

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Authors: Pradip Kundu, Samarjit Kar, Manoranjan Maiti

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In this paper, some practical solid transportation models are formulated considering per trip capacity of each type of conveyances with crisp and rough unit transportation costs. This is applicable for the system in which full vehicles, e.g. trucks, rail coaches are to be booked for transportation of products so that transportation cost is determined on the full of the conveyances. The models with unit transportation costs as rough variables are transformed into deterministic forms using rough chance constrained programming with the help of trust measure. Numerical examples are provided to illustrate the proposed models in crisp environment as well as with unit transportation costs as rough variables.

Keywords: Solid transportation problem, Rough set, Rough variable, Trust measure.

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Authors: Aicha Baya Goumeidane, Nafaa. Nacereddine

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A welded structure must be inspected to guarantee that the weld quality meets the design requirements to assure safety and reliability. However, X-ray image analyses and defect recognition with the computer vision techniques are very complex. Most difficulties lie in finding the small, irregular defects in poor contrast images which requires pre processing to image, extract, and classify features from strong background noise. This paper addresses the issue of designing methodology to extract defect from noisy background radiograph with image processing. Based on the use of actives contours this methodology seems to give good results

Keywords: Welding, Radiography, Computer vision, Active contour.

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Authors: Ilona I. Iatcheva, Rumena D. Stancheva, Mario Metodiev

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The paper deals with determination of electromagnetic and temperature field distribution of induction heating system used for pipe brazing. The problem is considered as coupled – time harmonic electromagnetic and transient thermal field. It has been solved using finite element method. The detailed maps of electromagnetic and thermal field distribution have been obtained. The good understanding of the processes in the considered system ensures possibilities for control, management and increasing the efficiency of the welding process.

Keywords: Electromagnetic field, temperature field, finiteelement method, induction heating, pipe brazing.

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Authors: Hannachi Med Tahar, H. Djebaili, B. Daheche

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In this approach, we have tried to describe the flattening of welded tubes, and its experimental application. The test is carried out at the (National product processing company dishes and tubes production). Usually, the final products (tubes) undergo a series of non-destructive inspection online and offline welding, and obviously destructive mechanical testing (bending, flattening, flaring, etc.). For this and for the purpose of implementing the flattening test, which applies to the processing of round tubes in other forms, it took four sections of welded tubes draft (before stretching hot) and welded tubes finished (after drawing hot and annealing), it was also noted the report 'health' flattened tubes must not show or crack or tear. The test is considered poor if it reveals a lack of ductility of the metal.

Keywords: Flattening, destructive testing, tube drafts, finished tube, Castem 2001.

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Authors: Juyi Park, Jung-Min Kim, Hee-Hwan Park, Jin-Wook Kim, Gye-Hyung Kang, Soo-Ho Kim

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This paper presents an iterative algorithm to find a inverse kinematic solution of 5-DOF robot. The algorithm is to minimize the iteration number. Since the 5-DOF robot cannot give full orientation of tool. Only z-direction of tool is satisfied while rotation of tool is determined by kinematic constraint. This work therefore described how to specify the tool direction and let the tool rotation free. The simulation results show that this algorithm effectively worked. Using the proposed iteration algorithm, error due to inverse kinematics converged to zero rapidly in 5 iterations. This algorithm was applied in real welding robot and verified through various practical works.

Keywords: 5-DOF manipulator, Inverse kinematics, Iterative algorithm, Wrist offset.

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Authors: Mabel A. Leva

Abstract:

This study defines a methodology to compute unitary costs for freight transportation modes. The main objective was to gather relevant costs data to support the formulation and evaluation of railway, road, pipelines and port projects. This article will concentrate on the following steps: Compilation and analysis of relevant modal cost studies, Methodological adjustments to make cost figures comparable between studies, Definition of typology and scope of transportation modes, Analysis and validation of cost values for relevant freight transportation modes in Chile. In order to define the comparison methodology for the costs between the different transportation modes, it was necessary to consider that the relevant cost depends on who performs the comparison. Thus, for the transportation user (e.g. exporter) the pertinent costs are the mode tariffs, whereas from the operators perspective (e.g. rail manager), the pertinent costs are the operating costs of each mode.

Keywords: Intermodal costs, Logistics, Transportation costs.

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Authors: Esther T. Akinlabi, Stephen A. Akinlabi

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The design of temperature measuring approach for a re-configured milling machine to produce friction stir welds is reported in this paper. The product design specifications for the redesigning of a milling machine were first outlined and the ranking criteria were determined. Three different concepts were generated for the temperature measurement on the reconfigured system and the preferred or the best concept was selected based on the set design ranking criteria. Further simulation and performance analysis was then conducted on the concept. The Infrared Thermography (IRT) concept was selected for the temperature measurement among other concepts generated because it is an ideal and most effective system of measurement in this regard.

Keywords: Clamping system, Friction Stir Welding, Reconfiguration, Support systems.

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Authors: Juraj Camaj, Martin Kendra, Jaroslav Masek

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The paper is focused to the evaluation railway tracks in the Slovakia by using Multi-Criteria method. Evaluation of railway tracks has important impacts for the assessment of investment in technical equipment. Evaluation of railway tracks also has an important impact for the allocation of marshalling yards. Marshalling yards are in transport model as centers for the operation assigned catchment area. This model is one of the effective ways to meet the development strategy of the European Community's railways. By applying this model in practice, a transport company can guarantee a higher quality of service and then expect an increase in performance. The model is also applicable to other rail networks. This model supplements a theoretical problem of train formation problem of new ways of looking at evaluation of factors affecting the organization of wagon flows.

Keywords: Railway track, multi-criteria methods, evaluation, transportation model.

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Authors: K. Farhangdoost, H. Heirani

Abstract:

Contact stress is an important problem in industry. This is a problem that in the first attention may be don-t appears, but disregard of these stresses cause a lot of damages in machines. These stresses occur at locations such as gear teeth, bearings, cams and between a locomotive wheel and the railroad rail. These stresses cause failure by excessive elastic deformation, yielding and fracture. In this paper we intend show the effective parameters in contact stress and ponder effect of curvature. In this paper we study contact stresses on the surface of gear teeth and compare these stresses for four popular profiles of gear teeth (involute, cycloid, epicycloids, and hypocycloid). We study this problem with mathematical and finite element methods and compare these two methods on different profile surfaces.

Keywords: Contact stress, Cycloid, Epicycloids, Finite element, Gear, Hypocycloid, Involute, Radius of curvature.

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Authors: Kainat Affrin, P. Reshma, G. Narendra Kumar

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Optimization of timetable is the need of the day for the rescheduling and routing of trains in real time. Trains are scheduled in parallel with the road transport vehicles to the same destination. As the number of trains is restricted due to single track, customers usually opt for road transport to use frequently. The air pollution increases as the density of vehicles on road transport is increased. Use of an alternate mode of transport like train helps in reducing air-pollution. This paper mainly aims at attracting the passengers to Train transport by proper rescheduling of trains using hybrid of stop-skip algorithm and iterative convex programming algorithm. Rescheduling of train bi-directionally is achieved on a single track with dynamic dual time and varying stops. Introduction of more trains attract customers to use rail transport frequently, thereby decreasing the pollution. The results are simulated using Network Simulator (NS-2).

Keywords: Air pollution, routing protocol, network simulator, rescheduling.

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Authors: Richard E. Miller

Abstract:

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.

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Authors: Kuen-Ming Shu, Cheng-Yu Chen

Abstract:

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: Esther T. Akinlabi, Stephen A. Akinlabi

Abstract:

This paper reports the tensile fracture location characterizations of dissimilar friction stir welds between 5754 aluminium alloy and C11000 copper. The welds were produced using three shoulder diameter tools; namely, 15, 18 and 25 mm by varying the process parameters. The rotational speeds considered were 600, 950 and 1200 rpm while the feed rates employed were 50, 150 and 300 mm/min to represent the low, medium and high settings respectively. The tensile fracture locations were evaluated using the optical microscope to identify the fracture locations and were characterized. It was observed that 70% of the tensile samples failed in the Thermo Mechanically Affected Zone (TMAZ) of copper at the weld joints. Further evaluation of the fracture surfaces of the pulled tensile samples revealed that welds with low Ultimate Tensile Strength either have defects or intermetallics present at their joint interfaces.

Keywords: fracture location, friction stir welding, intermetallics, metallography,

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Authors: A. Mojtaba Aghajani, B. Leila Shavakhi

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Energy intensity(energy consumption intensity) is a global index which computes the required energy for producing a specific value of goods and services in each country. It is computed in terms of initial energy supply or final energy consumption. In this study (research) Divisia method is used to decompose energy consumption and energy intensity. This method decomposes consumption and energy intensity to production effects, structural and net intensity and could be done as time series or two-periodical. This study analytically investigates consumption changes and energy intensity on economical sectors of Iran and more specific on road transportation(rail road and road).Our results show that the contribution of structural effect (change in economical activities combination) is very low and the effect of net energy consumption has the higher contribution in consumption changes and energy intensity. In other words, the high consumption of energy is due to Intensity of energy consumption and is not to structural effect of transportation sector.

Keywords: Divisia Method, Energy Intensity, Net IntensityEffect, Road Transportation , Structural Effect.

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