Search results for: Weld line displacement.

Authors: Amir Ansari, Ehsan Shahrjerdi, Ehsan Amini

Abstract:

To investigate the behavior of sheet metals during forming tailor welded blanks (TWB) of various thickness made via Co2 Laser welding are under consideration. These blanks are formed used two different forming methods of rubber as well as the conventional punch and die methods. The main research objective is the effects of using a rubber die instead of a solid one the displacement of the weld line and the press force needed for forming. Specimens with thicknesses of 0.5, 0.6, 0.8 and 1mm are subjected to Erichsen two dimensional tests and the resulted force for each case are compared. This is followed by a theoretical and numerical study of press force and weld line displacement. It is concluded that using rubber pad forming (RPF) causes a reduction in weld line displacement and an increase in the press force.

Keywords: Rubber pad forming, Tailor welded blank, Thickness ratio, Weld line displacement.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 1572

Authors: Shakil A. Kagzi, Sanjay Patil, Harit K. Raval

Abstract:

Tailor Welded Blanks (TWB) are utilized in automotive industries widely because of their advantage of weight and cost reduction and maintaining required strength and structural integrity. TWB consist of two or more sheet having dissimilar or similar material and thickness; welded together to form a single sheet before forming it to desired shape. Forming of the tailor welded blank is affected by ratio of thickness of blanks, ratio of their strength, etc. mainly due to in-homogeneity of material. In the present work the relative effect of these parameters on weld line movement is studied during deep drawing of TWB using FE simulation using HYPERWORKS. The simulation is validated with results from the literature. Simulations were than performed based on Taguchi orthogonal array followed by the ANOVA analysis to determine the significance of these parameters on forming of TWB.

Keywords: ANOVA, Deep drawing, Tailor Welded Blank, TWB, Weld line movement.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 2747

Authors: Julio Molleda, Daniel F. García, Juan C. Granda, Francisco J. Suárez

Abstract:

One of the main trouble in a steel strip manufacturing line is the breakage of whatever weld carried out between steel coils, that are used to produce the continuous strip to be processed. A weld breakage results in a several hours stop of the manufacturing line. In this process the damages caused by the breakage must be repaired. After the reparation and in order to go on with the production it will be necessary a restarting process of the line. For minimizing this problem, a human operator must inspect visually and manually each weld in order to avoid its breakage during the manufacturing process. The work presented in this paper is based on the Bayesian decision theory and it presents an approach to detect, on real-time, steel strip defective welds. This approach is based on quantifying the tradeoffs between various classification decisions using probability and the costs that accompany such decisions.

Keywords: Classification, Pattern Recognition, ProbabilisticReasoning, Statistical Data Analysis.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 1365

Authors: Norasiah Muhammad, Yupiter HP Manurung

Abstract:

This paper investigates the development of weld zone in Resistance Spot Welding (RSW) which focuses on weld nugget and Heat Affected Zone (HAZ). The effects of four factors namely weld current, weld time, electrode force and hold time were studied using a general 24 factorial design augmented by five centre points. The results of the analysis showed that all selected factors except hold time exhibit significant effect on weld nugget radius and HAZ size. Optimization of the welding parameters (weld current, weld time and electrode force) to normalize weld nugget and to minimize HAZ size was then conducted using Central Composite Design (CCD) in Response Surface Methodology (RSM) and the optimum parameters were determined. A regression model for radius of weld nugget and HAZ size was developed and its adequacy was evaluated. The experimental results obtained under optimum operating conditions were then compared with the predicted values and were found to agree satisfactorily with each other

Keywords: Factorial design, Optimization, Resistance Spot Welding (RSW), Response Surface Methodology (RSM).

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 3374

Authors: Essam A. Al-Bahkali, Mahir H. Es-saheb, Jonny Herwan

Abstract:

In this study the elastic-plastic stress distribution in weld-bonded joint, fabricated from austenitic stainless steel (AISI 304) sheet of 1.00 mm thickness and Epoxy adhesive Araldite 2011, subjected to axial loading is investigated. This is needed to improve design procedures and welding codes, and saving efforts in the cumbersome experiments and analysis. Therefore, a complete 3-D finite element modelling and analysis of spot welded, bonded and weld-bonded joints under axial loading conditions is carried out. A comprehensive systematic experimental program is conducted to determine many properties and quantities, of the base metals and the adhesive, needed for FE modelling, such like the elastic – plastic properties, modulus of elasticity, fracture limit, the nugget and heat affected zones (HAZ) properties, etc. Consequently, the finite element models developed, for each case, are used to evaluate stresses distributions across the entire joint, in both the elastic and plastic regions. The stress distribution curves are obtained, particularly in the elastic regions and found to be consistent and in excellent agreement with the published data. Furthermore, the stresses distributions are obtained in the weld-bonded joint and display the best results with almost uniform smooth distribution compared to spot and bonded cases. The stress concentration peaks at the edges of the weld-bonded region, are almost eliminated resulting in achieving the strongest joint of all processes.

Keywords: Spot Welded, Weld-Bonded, Load-Displacement curve, Stress distribution

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 2528

Authors: Nafaâ Nacereddine, Latifa Hamami, Djemel Ziou

Abstract:

In non destructive testing by radiography, a perfect knowledge of the weld defect shape is an essential step to appreciate the quality of the weld and make decision on its acceptability or rejection. Because of the complex nature of the considered images, and in order that the detected defect region represents the most accurately possible the real defect, the choice of thresholding methods must be done judiciously. In this paper, performance criteria are used to conduct a comparative study of thresholding methods based on gray level histogram, 2-D histogram and locally adaptive approach for weld defect extraction in radiographic images.

Keywords: 1D and 2D histogram, locally adaptive approach, performance criteria, radiographic image, thresholding, weld defect.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 2288

Authors: Y. Boutiche, N. Ramou, M. Ben Gharsallah

Abstract:

This paper is devoted to present and discuss a model that allows a local segmentation by using statistical information of a given image. It is based on Chan-Vese model, curve evolution, partial differential equations and binary level sets method. The proposed model uses the piecewise constant approximation of Chan-Vese model to compute Signed Pressure Force (SPF) function, this one attracts the curve to the true object(s)-s boundaries. The implemented model is used to extract weld defects from weld radiographic images in the aim to calculate the perimeter and surfaces of those weld defects; encouraged resultants are obtained on synthetic and real radiographic images.

Keywords: Active contour, Chan-Vese Model, local segmentation, weld radiographic images.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 1458

Authors: Chaitanya Sharma, Vikas Upadhyay, A. Tripathi

Abstract:

Friction stir welding and tungsten inert gas welding techniques were employed to weld armor grade aluminum alloy to investigate the effect of welding processes on tensile behavior of weld joints. Tensile tests, Vicker microhardness tests and optical microscopy were performed on developed weld joints and base metal. Welding process influenced tensile behavior and microstructure of weld joints. Friction stir welded joints showed tensile behavior better than tungsten inert gas weld joints.

Keywords: Friction stir welding, microstructure, tensile properties and fracture locations.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 2286

Authors: M. S. Kaiser

Abstract:

An attempt has been made to determine the strength and impact properties of Cr-Mo steel weld and base materials by varying the current during manual metal arc welding. Toughness over a temperature range from -32 to 100°C of base, heat affected zone (HAZ) and weld zones at three current settings are made. It is observed that the deterioration in notch toughness at any zone with the temperature decreases. The values of notch toughness for all zones at -32°C are almost same for any current settings. The values of notch toughness at HAZ area are higher than that of weld area due to the coarsening of ferrite grain of HAZ occurs with higher heat input. From microhardness and microstructure result, it can be concluded that large inclusion content in weld deposit is the cause of lower notch toughness value.

Keywords: Chromium-Molybdenum steel, post-weld heat treatment, heat affected zone, microstructure.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 3602

Authors: N. Nacereddine, L. Hamami, M. Tridi, N. Oucief

Abstract:

In non destructive testing by radiography, a perfect knowledge of the weld defect shape is an essential step to appreciate the quality of the weld and make decision on its acceptability or rejection. Because of the complex nature of the considered images, and in order that the detected defect region represents the most accurately possible the real defect, the choice of thresholding methods must be done judiciously. In this paper, performance criteria are used to conduct a comparative study of four non parametric histogram thresholding methods for automatic extraction of weld defect in radiographic images.

Keywords: Radiographic images, non parametric methods, histogram thresholding, performance criteria.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 2966

Authors: Khaled Alawadhi, Abdulkareem Aloraier, Suraj Joshi, Jalal Alsarraf

Abstract:

The aim of this paper is to compare the effectiveness and electrochemical behavior of typical oilfield corrosion inhibitors with previous oilfield corrosion inhibitors under the same electrochemical techniques to control preferential weld corrosion of X65 pipeline steel in artificial seawater saturated with carbon dioxide at a pressure of one bar. A secondary aim is to investigate the conditions under which current reversal takes place. A flow channel apparatus was used in the laboratory to simulate the actual condition that occurs in marine pipelines. Different samples from the parent metal, the weld metal and the heat affected zone in the pipeline steel were galvanically coupled. The galvanic currents flowing between the weld regions were recorded using zero-resistance ammeters and tested under static and flowing conditions in both inhibited and uninhibited media. The results show that a current reversal took place when 30ppm of both green oilfield inhibitors were present, resulting in accelerated weld corrosion.

Keywords: Carbon dioxide, carbon steel, current reversal, inhibitor, weld corrosion.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 2863

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

Abstract:

Aluminium and its alloys 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 ageing and combination of solution heat treatment and artificial aging are given to TIG welded aluminium joints. Mechanical and metallurgical properties of As welded joints of the aluminium alloys and post weld heat treated joints of the aluminium alloys were examined.

Keywords: Aluminium Alloys, Post weld Heat Treatment, TIG welding.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 3210

Authors: Iman Hadipour, Javad Marzbanrad

Abstract:

In this paper, the strength of a stabilizer is determined when the static and fatigue multiaxial loading are applied. Stabilizer is a part of suspension system in the heavy truck for stabilizing the cabin against the vibration of the road which composes of a thin-walled tube joined to a forge component by fillet weld. The component is loaded by non proportional random sequence of torsion and bending. Residual stress of welding process is considered here for static loading. This static loading with road irregularities are applied in this study as fatigue case that can affected in the fillet welded area of this part. The stresses in the welded structure are calculated using FEA. In addition, the fatigue with multi axial loading in the fillet weld is also investigated and the critical zone of the stabilizer is specified and presented by graphs. Residual stresses that have been resulted by the thermal forces are considered in FEA. Force increasing is the element of finding the critical point of the component.

Keywords: Fillet weld, fatigue, weld toe crack, weld root crack, S-N curve, multiaxial load, residual stress, combined force.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 2005

Authors: Jae-Kyung Lee, Nam-Joon Jung, Byung-Hak Cho

Abstract:

The line sleeves on power transmission line connects two conductors while the transmission line is constructing. However, the line sleeves sometimes cause transmission line break down, because the line sleeves are deteriorated and decayed by acid rain. When the transmission line is broken, the economical loss is huge. Therefore the line sleeves on power transmission lines should be inspected periodically to prevent power failure. In this paper, Korea Electric Power Research Institute reviewed several robots to inspect line status and proposes a robot to inspect line sleeve by measuring magnetic field on line sleeve. The developed inspection tool can reliable to move along transmission line and overcome several obstacles on transmission line. The developed system is also applied on power transmission line and verified the efficiency of the robot.

Keywords: Transmission line inspection, line sleeve, transmission line inspection robot, line sleeve inspection

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 2225

Authors: M. Avinash, G. V. K. Chaitanya, Dhananjay Kumar Giri, Sarala Upadhya, B. K. Muralidhara

Abstract:

Ti-6Al-4V alloy has demonstrated a high strength to weight ratio as well as good properties at high temperature. The successful application of the alloy in some important areas depends on suitable joining techniques. Friction welding has many advantageous features to be chosen for joining Titanium alloys. The present work investigates the feasibility of producing similar metal joints of this Titanium alloy by rotary friction welding method. The joints are produced at three different speeds and the performances of the welded joints are evaluated by conducting microstructure studies, Vickers Hardness and tensile tests at the joints. It is found that the weld joints produced are sound and the ductile fractures in the tensile weld specimens occur at locations away from the welded joints. It is also found that a rotational speed of 1500 RPM can produce a very good weld, with other parameters kept constant.

Keywords: Rotary friction weld, rotational speed, Ti-6Al-4V, weld structures.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 2547

Authors: Pradeep M., N. S. Mahesh, Raja Hussain

Abstract:

Resistance spot welding (RSW) has been used widely to join sheet metals. It has been a challenge to get required weld quality in spot welding of dissimilar thickness materials. Weld parameters are not generally available in standards for thickness beyond 4mm. This paper presents the welding process design and parameter optimization of RSW used in joining of low carbon steel sheet of thickness 0.8 mm and metal strips of cross section 10 x 5mm for electrical motor applications. Taguchi quality design was adopted for weld current and time optimization using L9 orthogonal array. Optimum process parameters (current- 3.5kA and time- 10 cycles) were obtained from the Taguchi analysis and shear test results. Confirmation experiment result revealed that the weld quality was within acceptable interval. Further, numerical simulation of RSW process was carried out with selected weld parameters to quantify the temperature at faying surface and check for formation of appropriate nugget. The nugget geometry measured after peel test and predicted from numerical validation method were similar and in accordance with the standards.

Keywords: Resistance spot welding, dissimilar thickness, weld parameters, Taguchi method, numerical modeling.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 5139

Authors: Ziad. Sh. Al Sarraf

Abstract:

Ultrasonic metal welding has been the subject of ongoing research and development, most recently concentrating on metal joining in miniature devices, for example to allow solder-free wire bonding. As well as at the small scale, there are also opportunities to research the joining of thicker sheet metals and to widen the range of similar and dissimilar materials that can be successfully joined using this technology. This study presents the design, characterisation and test of a lateral-drive ultrasonic metal spot welding device. The ultrasonic metal spot welding horn is modelled using finite element analysis (FEA) and its vibration behaviour is characterised experimentally to ensure ultrasonic energy is delivered effectively to the weld coupon. The welding stack and fixtures are then designed and mounted on a test machine to allow a series of experiments to be conducted for various welding and ultrasonic parameters. Weld strength is subsequently analysed using tensile-shear tests. The results show how the weld strength is particularly sensitive to the combination of clamping force and ultrasonic vibration amplitude of the welding tip, but there are optimal combinations of these and also limits that must be clearly identified.

Keywords: Ultrasonic welding, vibration amplitude, welding force, weld strength.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 2126

Authors: F. Roger, A. Traidia, B. Reynier

Abstract:

Arc welding creates a weld pool to realize continuity between pieces of assembly. The thermal history of the weld is dependent on heat transfer and fluid flow in the weld pool. The metallurgical transformation during welding and cooling are modeled in the literature only at solid state neglecting the fluid flow. In the present paper we associate a heat transfer – fluid flow and metallurgical model for the 16MnD5 steel. The metallurgical transformation model is based on Leblond model for the diffusion kinetics and on the Koistinen-Marburger equation for Marteniste transformation. The predicted thermal history and metallurgical transformations are compared to a simulation without fluid phase. This comparison shows the great importance of the fluid flow modeling.

Keywords: Arc welding, Weld pool, Fluid flow, Metallurgical transformations.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 1549

Authors: Kezia Amanda Kurniadi, Emre Islamoglu, Kwangyeol Ryu

Abstract:

As there has been a recognizable transition in automotive industry from mass production to mass customization, automobile manufacturers and their suppliers have been seeking ways for more flexible and efficient processes. Eventually, modular production is currently being applied to manage the changing orders of the industry. In this paper, two different modular assembly line concepts were studied: conveyor line and box assembly line. Mathematical model for two assembly line concepts were developed and their production line efficiency were compared as a performance measure to improve their assembly line balancing.

Keywords: Line Efficiency, Box assembly line, Conventional conveyor line

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 2921

Authors: A. Hadjadj, S. Maamir

Abstract:

Since the advent of the law 86/14 concerning the
exploitation of the national territory by foreign companies in
partnership with the Algerian oil and gas company, the problem of
hydrocarbons metering in the sharing production come out.
More generally, good management counting hydrocarbons can
provide data on the production wells, the field and the reservoir for
medium and long term planning, particularly in the context of the
management and field development.
In this work, we are interested in the transactional metering which
is a very delicate and crucial period in the current context of the new
hydrocarbon’s law characterized by assets system between the
various activities of Sonatrach and its foreign partners.
After a state of the art on hydrocarbons metering devices in
Algeria and elsewhere, we will decline the advantages and
disadvantages of each system, and then we describe the problem to
try to reach an optimal solution.

Keywords: Flowmeter orifice, heat flow, Sonatrach, Transactional metering.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 1387

Authors: Tosapolporn Pornpibunsompop

Abstract:

The non-destructive testing of launch tube weld with radiography was investigated and evaluated with AWS D1.1 standard. The paper started with preparation of launch tube and radiographic inspection. X-Ray inspection then was done and gotten the result. The judgment of inspection results were concluded by certified person and finally, the evaluation with AWS D1.1 standard was conducted as well. The result shown that weld position P1 was not conformed to AWS D1.1 which allowed size of incomplete penetration did not exceed 4 mm. The other welds were corresponded to as mentioned standard. Additionally, the corrective actions for incomplete penetration either provided for future actions.

Keywords: Non-destructive evaluation, Weld, Launch tube, Radiography

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 1622

Authors: Essam A. Al-Bahkali

Abstract:

A three-dimensional finite element modeling for austenitic stainless steel AISI 304 annealed condition sheets of 1.0 mm thickness are developed using ABAQUS® software. This includes spot welded and weld bonded joints models. Both models undergo thermal heat caused by spot welding process and then are subjected to axial load up to the failure point. The properties of elastic and plastic regions, modulus of elasticity, fracture limit, nugget and heat affected zones are determined. Complete loaddisplacement curve for each joining model is obtained and compared with the experiment data and with the finite element models without including the effect of thermal process. In general, the results obtained for both spot welded and weld-bonded joints affected by thermal process showed an excellent agreement with the experimental data.

Keywords: Heat Affected Zone, Spot Welded, Thermal Process, Weld-Bonded.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 1547

Authors: M. Tridi, N. Nacereddine, N. Oucief

Abstract:

This paper describes a novel method for automatic estimation of the contours of weld defect in radiography images. Generally, the contour detection is the first operation which we apply in the visual recognition system. Our approach can be described as a region based maximum likelihood formulation of parametric deformable contours. This formulation provides robustness against the poor image quality, and allows simultaneous estimation of the contour parameters together with other parameters of the model. Implementation is performed by a deterministic iterative algorithm with minimal user intervention. Results testify for the very good performance of the approach especially in synthetic weld defect images.

Keywords: Contour, gaussian, likelihood, rayleigh.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 1607

Authors: Ramesh S., Sasiraaju A. S., Sidhaarth K., Sudhan Rajkumar N., Manivel Muralidaran V.

Abstract:

This work presents the result of investigations aimed at determining the hardness of the welded Chromoly (A 4130) steel plate of 2” thickness. Multi pass welding for the thick sections was carried out and analyzed for the Chromoly alloy steel plates. The study of hardness at the weld metal reveals that there is the presence of different micro structure products which yields diverse properties. The welding carried out using GMAW with ER70s-2 electrode. Single V groove design was selected for the butt joint configuration. The presence of hydrogen has been suppressed by selecting low hydrogen electrode. Preheating of the plate prior to welding reduces the cooling rate which also affects the weld metal microstructure. The shielding gas composition used in this analysis is 80% Ar-20% CO2. The experimental analysis gives the detailed study of the hardness of the material.

Keywords: Chromoly, Gas Metal Arc Weld (GMAW), Hardness, Multi pass weld, Shielding gas composition.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 2948

Authors: A. Nait Salah, M. Kaddami

Abstract:

This work describes an investigation on the effect of filler metals diameter to weld joint, and low alloy carbon steel A516 Grade 70 is the base metal. Commercially SA516 Grade70 is frequently used for the manufacturing of pressure vessels, boilers and storage tank, etc. In fabrication industry, the hardness of the weld joint is between the important parameters to check, after heat treatment of the weld. Submerged arc welding (SAW) is used with two filler metal diameters, and this solid wire electrode is used for SAW non-alloy and for fine grain steels (SFA 5.17). The different diameters were selected (Ø = 2.4 mm and Ø = 4 mm) to weld two specimens. Both specimens were subjected to the same preparation conditions, heat treatment, macrograph, metallurgy micrograph, and micro-hardness test. Samples show almost similar structure with highest hardness. It is important to indicate that the thickness used in the base metal is 22 mm, and all specifications, preparation and controls were according to the ASME section IX. It was observed that two different filler metal diameters performed on two similar specimens demonstrated that the mechanical property (hardness) increases with decreasing diameter. It means that even the heat treatment has the same effect with the same conditions, the filler metal diameter insures a depth weld penetration and better homogenization. Hence, the SAW welding technique mentioned in the present study is favorable to implicate for the industry using the small filler metal diameter.

Keywords: ASME, base metal, filler metal, micro-hardness test, submerged arc welding.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 802

Authors: Paua Ketan, Bhagate Rajkumar, Adiga Ganesh, M. Kiran

Abstract:

Low gear noise is an important sound quality feature in modern passenger cars. Annoying gear noise from the gearbox is influenced by the gear design, gearbox shaft layout, manufacturing deviations in the components, assembly errors and the mounting arrangement of the complete gearbox. Geometrical deviations in the form of profile and lead errors are often present on the flanks of the inspected gears. Ghost frequencies of a gear are very challenging to identify in standard gear measurement and analysis process due to small wavelengths involved. In this paper, gear whine noise occurring at non-integral multiples of gear mesh frequency of passenger car gearbox is investigated and the root cause is identified using the displacement deviation analysis (DDA) method. DDA method is applied to identify ghost frequency excitations on the flanks of gears arising out of generation grinding. Frequency identified through DDA correlated with the frequency of vibration and noise on the end-of-line machine as well as vehicle level measurements. With the application of DDA method along with standard lead profile measurement, gears with ghost frequency geometry deviations were identified on the production line to eliminate defective parts and thereby eliminate ghost frequency noise from a vehicle. Further, displacement deviation analysis can be used in conjunction with the manufacturing process simulation to arrive at suitable countermeasures for arresting the ghost frequency.

Keywords: Displacement deviation analysis, gear whine, ghost frequency, sound quality.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 694

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

Abstract:

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.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 873

Authors: Mahmoud M. S. Albattah

Abstract:

In this paper, to optimize the “Characteristic Straight Line Method" which is used in the soil displacement analysis, a “best estimate" of the geodetic leveling observations has been achieved by taking in account the concept of 'Height systems'. This concept has been discussed in detail and consequently the concept of “height". In landslides dynamic analysis, the soil is considered as a mosaic of rigid blocks. The soil displacement has been monitored and analyzed by using the “Characteristic Straight Line Method". Its characteristic components have been defined constructed from a “best estimate" of the topometric observations. In the measurement of elevation differences, we have used the most modern leveling equipment available. Observational procedures have also been designed to provide the most effective method to acquire data. In addition systematic errors which cannot be sufficiently controlled by instrumentation or observational techniques are minimized by applying appropriate corrections to the observed data: the level collimation correction minimizes the error caused by nonhorizontality of the leveling instrument's line of sight for unequal sight lengths, the refraction correction is modeled to minimize the refraction error caused by temperature (density) variation of air strata, the rod temperature correction accounts for variation in the length of the leveling rod' s Invar/LO-VAR® strip which results from temperature changes, the rod scale correction ensures a uniform scale which conforms to the international length standard and the introduction of the concept of the 'Height systems' where all types of height (orthometric, dynamic, normal, gravity correction, and equipotential surface) have been investigated. The “Characteristic Straight Line Method" is slightly more convenient than the “Characteristic Circle Method". It permits to evaluate a displacement of very small magnitude even when the displacement is of an infinitesimal quantity. The inclination of the landslide is given by the inverse of the distance reference point O to the “Characteristic Straight Line". Its direction is given by the bearing of the normal directed from point O to the Characteristic Straight Line (Fig..6). A “best estimate" of the topometric observations was used to measure the elevation of points carefully selected, before and after the deformation. Gross errors have been eliminated by statistical analyses and by comparing the heights within local neighborhoods. The results of a test using an area where very interesting land surface deformation occurs are reported. Monitoring with different options and qualitative comparison of results based on a sufficient number of check points are presented.

Keywords: Characteristic straight line method, dynamic height, landslides, orthometric height, systematic errors.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 1524

Authors: Ahmad Fahim Nasiry, Shigeo Honma

Abstract:

We examine two-dimensional oil displacement by water in a petroleum reservoir. The pore fluid is immiscible, and the porous media is homogenous and isotropic in the horizontal direction. Buckley-Leverett theory and a combination of Laplacian and Darcy’s law are used to study the fluid flow through porous media, and the Laplacian that defines the dispersion and diffusion of fluid in the sand using heavy oil is discussed. The reservoir is homogenous in the horizontal direction, as expressed by the partial differential equation. Two main factors which are observed are the water saturation and pressure distribution in the reservoir, and they are evaluated for predicting oil recovery in two dimensions by a physical and mathematical simulation model. We review the numerical simulation that solves difficult partial differential reservoir equations. Based on the numerical simulations, the saturation and pressure equations are calculated by the iterative alternating direction implicit method and the iterative alternating direction explicit method, respectively, according to the finite difference assumption. However, to understand the displacement of oil by water and the amount of water dispersion in the reservoir better, an interpolated contour line of the water distribution of the five-spot pattern, that provides an approximate solution which agrees well with the experimental results, is also presented. Finally, a computer program is developed to calculate the equation for pressure and water saturation and to draw the pressure contour line and water distribution contour line for the reservoir.

Keywords: Numerical simulation, immiscible, finite difference, IADI, IADE, waterflooding.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 1040

Authors: A. Traidia, F. Roger, A. Chidley, J. Schroeder, T. Marlaud

Abstract:

A transient finite element model has been developed to study the heat transfer and fluid flow during spot Gas Tungsten Arc Welding (GTAW) on stainless steel. Temperature field, fluid velocity and electromagnetic fields are computed inside the cathode, arc-plasma and anode using a unified MHD formulation. The developed model is then used to study the influence of different helium-argon gas mixtures on both the energy transferred to the workpiece and the time evolution of the weld pool dimensions. It is found that the addition of helium to argon increases the heat flux density on the weld axis by a factor that can reach 6.5. This induces an increase in the weld pool depth by a factor of 3. It is also found that the addition of only 10% of argon to helium decreases considerably the weld pool depth, which is due to the electrical conductivity of the mixture that increases significantly when argon is added to helium.

Keywords: GTAW, Thermal plasmas, Fluid flow, Marangoni effect, Shielding Gases.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 3064