Search results for: breakage.

Authors: Bharatendra Rai

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Cutting tools are widely used in manufacturing processes and drilling is the most commonly used machining process. Although drill-bits used in drilling may not be expensive, their breakage can cause damage to expensive work piece being drilled and at the same time has major impact on productivity. Predicting drill-bit breakage, therefore, is important in reducing cost and improving productivity. This study uses twenty features extracted from two degradation signals viz., thrust force and torque. The methodology used involves developing and comparing decision tree, random forest, and multinomial logistic regression models for classifying and predicting drill-bit breakage using degradation signals.

Keywords: Degradation signal, drill-bit breakage, random forest, multinomial logistic regression.

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

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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.

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Authors: Sam S. Hashemi

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The breakage of bonding between sand particles and their dislodgment from the borehole wall are among the main factors resulting in a borehole failure in poorly cemented granular formations. The grain debonding usually precedes the borehole failure and it can be considered as a sign that the onset of the borehole collapse is imminent. Detecting the bonding breakage point and introducing an appropriate failure criterion will play an important role in borehole stability analysis. To study the influence of different factors on the initiation of sand bonding breakage at the borehole wall, a series of laboratory tests was designed and conducted on poorly cemented sand samples. The total absorbed strain energy per volume of material up to the point of the observed particle debonding was computed. The results indicated that the particle bonding breakage point at the borehole wall was reached both before and after the peak strength of the thick-walled hollow cylinder specimens depending on the stress path and cement content. Three different cement contents and two borehole sizes were investigated to study the influence of the bonding strength and scale on the particle dislodgment. Test results showed that the stress path has a significant influence on the onset of the sand bonding breakage. It was shown that for various stress paths, there is a near linear relationship between the absorbed energy and the normal effective mean stress.

Keywords: Borehole stability, experimental studies, total strain energy, poorly cemented sands, particle bonding breakage.

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Authors: Felix Platzer, Eric Fimbinger

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In Discrete Element Method (DEM) simulations, the breakage behavior of particles can be simulated based on different principles. In the case of large, complex-shaped particles that show various breakage patterns depending on the scenario leading to the failure and often only break locally instead of fracturing completely, some of these principles do not lead to realistic results. The reason for this is that in said cases, the methods in question, such as the Particle Replacement Method (PRM) or Voronoi Fracture, replace the initial particle (that is intended to break) into several sub-particles when certain breakage criteria are reached, such as exceeding the fracture energy. That is why those methods are commonly used for the simulation of materials that fracture completely instead of breaking locally. That being the case, when simulating local failure, it is advisable to pre-build the initial particle from sub-particles that are bonded together. The dimensions of these sub-particles  consequently define the minimum size of the fracture results. This structure of bonded sub-particles enables the initial particle to break at the location of the highest local loads – due to the failure of the bonds in those areas – with several sub-particle clusters being the result of the fracture, which can again also break locally. In this project, different methods for the generation and calibration of complex-shaped particle conglomerates using bonded particle modeling (BPM) to enable the ability to depict more realistic fracture behavior were evaluated based on the example of filter cake. The method that proved suitable for this purpose and which furthermore  allows efficient and realistic simulation of breakage behavior of complex-shaped particles applicable to industrial-sized simulations is presented in this paper.

Keywords: Bonded particle model (BPM), DEM, filter cake, particle breakage, particle fracture.

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Authors: M. Shaker, S. Minaei, M. H. Khoshtaghaza, A. Banakar, A. Jafari

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In this study a system of machine vision and singulation was developed to separate paddy from rice and determine paddy husking and rice breakage percentages. The machine vision system consists of three main components including an imaging chamber, a digital camera, a computer equipped with image processing software. The singulation device consists of a kernel holding surface, a motor with vacuum fan, and a dimmer. For separation of paddy from rice (in the image), it was necessary to set a threshold. Therefore, some images of paddy and rice were sampled and the RGB values of the images were extracted using MATLAB software. Then mean and standard deviation of the data were determined. An Image processing algorithm was developed using MATLAB to determine paddy/rice separation and rice breakage and paddy husking percentages, using blue to red ratio. Tests showed that, a threshold of 0.75 is suitable for separating paddy from rice kernels. Results from the evaluation of the image processing algorithm showed that the accuracies obtained with the algorithm were 98.36% and 91.81% for paddy husking and rice breakage percentage, respectively. Analysis also showed that a suction of 45 mmHg to 50 mmHg yielding 81.3% separation efficiency is appropriate for operation of the kernel singulation system.

Keywords: Computer vision, rice kernel, husking, breakage.

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Authors: C. R. Danielle, S. Erik, T. Patrick, M. Hugh

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In the last decade there has been an increase in demand for fine grinding due to the depletion of coarse-grained orebodies and an increase of processing fine disseminated minerals and complex orebodies. These ores have provided new challenges in concentrator design because fine and ultra-fine grinding is required to achieve acceptable recovery rates. Therefore, the correct design of a grinding circuit is important for minimizing unit costs and increasing product quality. The use of ball mills for grinding in fine size ranges is inefficient and, therefore, vertical stirred grinding mills are becoming increasingly popular in the mineral processing industry due to its already known high energy efficiency. This work presents a hypothesis of a methodology to predict the product size distribution of a vertical stirred mill using a Bond ball mill. The Population Balance Model (PBM) was used to empirically analyze the performance of a vertical mill and a Bond ball mill. The breakage parameters obtained for both grinding mills are compared to determine the possibility of predicting the product size distribution of a vertical mill based on the results obtained from the Bond ball mill. The biggest advantage of this methodology is that most of the minerals processing laboratories already have a Bond ball mill to perform the tests suggested in this study. Preliminary results show the possibility of predicting the performance of a laboratory vertical stirred mill using a Bond ball mill.

Keywords: Bond ball mill, population balance model, product size distribution, vertical stirred mill.

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Authors: Chun-Wei Huang, Jyh-Cherng Gu, Ming-Ta Yang

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Non-synchronous breakage or line failure in power systems with light or no loads can lead to core saturation in transformers or potential transformers. This can cause component and capacitance matching resulting in the formation of resonant circuits, which trigger ferroresonance. This study employed a wavelet transform for the detection of ferroresonance. Simulation results demonstrate the efficacy of the proposed method.

Keywords: Ferroresonance, Wavelet Transform, Intelligent Electronic Device, Transformer.

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Authors: J. Alizadeh K., R. S. Ashofteh, A. Asadi Lari

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Railway vehicle wheels are designed to operate in harsh environments and to withstand high hydrostatic contact pressures. This situation may result in critical circumstances, in particular wheel breakage. This paper presents a time history of a series of broken wheels during a time interval [2007-2008] belongs to locomotive fleet on Iranian Railways. Such fractures in locomotive wheels never reported before. Due to the importance of this issue, a research study has been launched to find the potential reasons of this problem. The authors introduce a FEM model to indicate how and where the wheels could have been affected during their operation. Then, the modeling results are presented and discussed in detail.

Keywords: Crack, fatigue, FE analysis, wheel.

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Authors: Majid Tolouei-Rad

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This paper describes a combined mathematicalgraphical approach for optimum tool path planning in order to improve machining efficiency. A methodology has been used that stabilizes machining operations by adjusting material removal rate in pocket milling operations while keeping cutting forces within limits. This increases the life of cutting tool and reduces the risk of tool breakage, machining vibration, and chatter. Case studies reveal the fact that application of this approach could result in a slight increase of machining time, however, a considerable reduction of tooling cost, machining vibration, noise and chatter can be achieved in addition to producing a better surface finish.

Keywords: CNC machines, milling, optimization, removal rate.

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Authors: Bo Wun Huang, Pu Ping Yu, Jao-Hwa Kuang

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For smaller mechatronic device, especially for micro Electronic system, a micro machining is a must. However, most investigations on vibration of a mill have been limited to the traditional type mill. In this article, vibration and dynamic characteristics of a micro mill were investigated in this study. The trend towards higher precision manufacturing technology requires producing miniaturized components. To improve micro-milled product quality, obtain a higher production rate and avoid milling breakage, the dynamic characteristics of micro milling must be studied. A stepped pre-twisted mill is used to simulate the micro mill. The finite element analysis is employed in this work. The flute length and diameter effects of the micro mill are considered. It is clear that the effects of micro mill shape parameters on vibration in a micro mill are significant.

Keywords: micro system, micro mill, vibration.

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Authors: T. Teruzzi, S. Antonietti, C. Mosca, C. Paglia

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This paper discusses the causes of the structural failure in a tower crane. The structural collapse occurred at the upper joints of the extension element used to increase the height of the crane. The extension element consists of a steel lattice structure made with angular profiles and plates joined to the tower element by arc welding. Macroscopic inspection of the sections showed that the break was always observed on the angular profiles at the weld bead edge. The case study shows how, using mechanical characterization, chemical analysis of the steel and macroscopic and microscopic metallographic examinations, it was possible to obtain significant evidence that identified the mechanism causing the breakage. The analyses identified the causes of the structural failure as the use of materials that were not suitable for welding and poor performance in the welding joints.

Keywords: Failure, weld, microstructure, microcracks.

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Authors: K. Geetha, P. Thangaraj

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Mobile Ad Hoc Networks (MANETs) is a collection of mobile devices forming a communication network without infrastructure. MANET is vulnerable to security threats due to network’s limited security, dynamic topology, scalability and the lack of central management. The Quality of Service (QoS) routing in such networks is limited by network breakage caused by node mobility or nodes energy depletions. The impact of node mobility on trust establishment is considered and its use to propagate trust through a network is investigated in this paper. This work proposes an enhanced Associativity Based Routing (ABR) with Fuzzy based Trust (Fuzzy- ABR) routing protocol for MANET to improve QoS and to mitigate network attacks.

Keywords: Mobile Ad hoc Networks (MANET), Associativity Based Routing (ABR), Fuzzy based Computed Trust.

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Authors: S. Ghorbani, N. I. Polushin

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Vibration during machining process is crucial since it affects cutting tool, machine, and workpiece leading to a tool wear, tool breakage, and an unacceptable surface roughness. This paper applies a nonparametric statistical method, single decision tree (SDT), to identify factors affecting on vibration in machining process. Workpiece material (AISI 1045 Steel, AA2024 Aluminum alloy, A48-class30 Gray Cast Iron), cutting tool (conventional, cutting tool with holes in toolholder, cutting tool filled up with epoxy-granite), tool overhang (41-65 mm), spindle speed (630-1000 rpm), feed rate (0.05-0.075 mm/rev) and depth of cut (0.05-0.15 mm) were used as input variables, while vibration was the output parameter. It is concluded that workpiece material is the most important parameters for natural frequency followed by cutting tool and overhang.

Keywords: Cutting condition, vibration, natural frequency, decision tree, CART algorithm.

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Authors: Jafar Hashemi, Reza Tabatabaekoloor, Toshinori Kimura

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The study of interaction among the grain, moisture, and the surrounding space (air) is key to understanding the graindrying process. In Iran, rice (mostly Indica type) is dried by flat bed type dryer until the final MC reaches to 6 to 8%. The experiments were conducted to examine the effect of application of discharge fan with different heights of paddy on the drying efficiency. Experiments were designed based on two different configurations of the drying methods; with and without discharge fan with three different heights of paddy including; 5, 10, and 15 cm. The humid heated air will be going out immediately by the suction of discharge fan. The drying time is established upon the average final MC to achieve about 8%. To save energy and reduce the drying time, the distribution of temperature between layers should be fast and uniform with minimum difference; otherwise the difference of MC gradient between layers will be high and will induce grain breakage. The difference of final MC between layers in the two methods was 48-73%. The steady state of temperature between the two methods has saved time in the range of 10-20%, and the efficiency of temperature distribution increased 17-26% by the use of discharge fan.

Keywords: FBT Dryer, Final MC, Discharge Fan.

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Authors: Hoda Molavi, Sima Hoseinpoor, Hossein Bahmanyar

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A Rotary Disc Contactor with inner diameter of 9.1cm and maximum operating height of 40cm has been used to investigate break up phenomenon. Water-Toluene, Water as continuous phase and Toluene as dispersed phase, was selected as chemical system in the experiments. The mentioned chemical system has high interfacial tension so it was possible to form big drops which permit accurate investigation on break up phenomenon as well as the first and second critical rotor speeds. In this study, Break up phenomenon has been studied as a function of mother drop size, rotor speed and continuous phase height. Further more; the effects of mother drop size and continuous phase height on the first and second critical rotor speeds were investigated. Finally, two modified correlations were proposed to estimate the first and second critical speeds.

Keywords: Breakage, First critical rotor speed, Rotary disccontactor, Second critical rotor speed

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Authors: Y. Hong, H. Y. Hu, A. Sakoda, M. Sagehashi

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In this study, inhibition of Microcystis aeruginosa by antialgal alleochemical gramine, was studied by analyzing algal metabolic activity (represented by esterase and total dehydrogenase activities) and cell ultrastructure (showing morphological and ultrastructure alterations using transmission electron microscopy and DNA ladder analysis). After gramine exposure, esterase and total dehydrogenase activities were increased firstly but decreased later. In contrast with the controls, the cells exposed to gramine showed apparent ultrastructure alterations with thylakoids in breakage, phycobilins in decrease, lipid and cyanophycin granules abundant firstly but dissolved afterwards, DNA in fragementation. The occurrence of increase of metabolic activity and specific granules reflected that the resistance of cellular response to gramine was initiated. DNA fragementation associated with the increase of metabolic activity and specific granules hinted that gramine caused M. aeruginosa cells to initiate some morphotype of programmed cell death.

Keywords: Allelochemical, gramine, metabolic activity, Microcystis aeruginosa, ultrastructure.

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Authors: Ding Jue, Li Jiahua, Lei Zhidi, Weng Peifen, Li Xiaowei

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With the rapid development of national modern industry, people begin to pay attention to environmental pollution and harm caused by industrial dust. Based on above, a numerical study on the dedusting technology of industrial environment was conducted. The dynamic models of multicomponent particles collision and coagulation, breakage and deposition are developed, and the interaction of water droplet and aerosol particle in 2-Dimension flow field was researched by Eulerian-Lagrangian method and Multi-Monte Carlo method. The effects of the droplet scale, movement speed of droplet and the flow field structure on scavenging efficiency were analyzed. The results show that under the certain condition, 30μm of droplet has the best scavenging efficiency. At the initial speed 1m/s of droplets, droplets and aerosol particles have more time to interact, so it has a better scavenging efficiency for the particle.

Keywords: Water droplet, aerosol particle, collision and coagulation, multi-Monte Carlo method.

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Authors: Othman Belgassim, Krzysztof Jemielniak

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The analysis of Acoustic Emission (AE) signal generated from metal cutting processes has often approached statistically. This is due to the stochastic nature of the emission signal as a result of factors effecting the signal from its generation through transmission and sensing. Different techniques are applied in this manner, each of which is suitable for certain processes. In metal cutting where the emission generated by the deformation process is rather continuous, an appropriate method for analysing the AE signal based on the root mean square (RMS) of the signal is often used and is suitable for use with the conventional signal processing systems. The aim of this paper is to set a strategy in tool failure detection in turning processes via the statistic analysis of the AE generated from the cutting zone. The strategy is based on the investigation of the distribution moments of the AE signal at predetermined sampling. The skews and kurtosis of these distributions are the key elements in the detection. A normal (Gaussian) distribution has first been suggested then this was eliminated due to insufficiency. The so called Beta distribution was then considered, this has been used with an assumed β density function and has given promising results with regard to chipping and tool breakage detection.

Keywords: AE signal, skew, kurtosis, tool failure

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Authors: Suleiman E. Al-lubani, Mohammad E. Matarneh, Hussien M. Al-Wedyan, Ala M. Rayes

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Aluminum alloy has an extensive range of industrial application due to its consistent mechanical properties and structural integrity. The heat treatment by precipitation technique affected the Magnesium, Silicon Manganese and copper crystals dissolved in the Aluminum alloy. The crystals dislocated to precipitate on the crystal’s boundaries of the Aluminum alloy when given a thermal energy increased its hardness. In this project various times and temperature were varied to find out the best combination of these variables to increase the precipitation of the metals on the Aluminum crystal’s boundaries which will lead to get the highest hardness. These specimens are then tested for their hardness and tensile strength. It is noticed that when the temperature increases, the precipitation increases and consequently the hardness increases. A threshold temperature value (264C0) of Aluminum alloy should not be reached due to the occurrence of recrystalization which causes the crystal to grow. This recrystalization process affected the ductility of the alloy and decrease hardness. In addition, and while increasing the temperature the alloy’s mechanical properties will decrease. The mechanical properties, namely tensile and hardness properties are investigated according to standard procedures. In this research, different temperature and time have been applied to increase hardening.The highest hardness at 100°c in 6 hours equals to 207.31 HBR, while at the same temperature and time the lowest elongation equals to 146.5.

Keywords: Aluminum alloy, recrystalization process, heat treatment, hardness properties, precipitation, intergranular breakage.

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Authors: Jayden Levy, Garth M. K. Pearce

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An automated fibre placement method has been developed to build through-thickness reinforcement into carbon fibre reinforced plastic laminates during their production, with the goal of increasing delamination fracture toughness while circumventing the additional costs and defects imposed by post-layup stitching and z-pinning. Termed ‘inter-weaving’, the method uses custom placement sequences of thermoset prepreg tows to distribute regular fibre link regions in traditionally clean ply interfaces. Inter-weaving’s impact on mode I delamination fracture toughness was evaluated experimentally through double cantilever beam tests (ASTM standard D5528-13) on [±15°]9 laminates made from Park Electrochemical Corp. E-752-LT 1/4” carbon fibre prepreg tape. Unwoven and inter-woven automated fibre placement samples were compared to those of traditional laminates produced from standard uni-directional plies of the same material system. Unwoven automated fibre placement laminates were found to suffer a mostly constant 3.5% decrease in mode I delamination fracture toughness compared to flat uni-directional plies. Inter-weaving caused significant local fracture toughness increases (up to 50%), though these were offset by a matching overall reduction. These positive and negative behaviours of inter-woven laminates were respectively found to be caused by fibre breakage and matrix deformation at inter-weave sites, and the 3D layering of inter-woven ply interfaces providing numerous paths of least resistance for crack propagation.

Keywords: AFP, automated fibre placement, delamination, fracture toughness, inter-weaving.

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Authors: G.–A. Constantin, G. Voicu, E.–M. Stefan, P. Tudor, G. Paraschiv, M.–G. Munteanu

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In the activity of handling and transport of food products, the products may be subjected to mechanical stresses that may lead to their deterioration by deformation, breaking, or crushing. This is the case for biscuits, regardless of their type (gluten-free or sugary), the addition of ingredients or flour from which they are made. However, gluten-free biscuits have a higher mechanical resistance to breakage or crushing compared to easily shattered sugar biscuits (especially those for children). The paper presents the results of the experimental evaluation of the texture for four varieties of commercial biscuits, using the penetrometer equipped with needle cone at five different additional weights on the cone-rod. The assortments of biscuits tested in the laboratory were Petit Beurre, Picnic, and Maia (all three manufactured by RoStar, Romania) and Sultani diet biscuits, manufactured by Eti Burcak Sultani (Turkey, in packs of 138 g). For the four varieties of biscuits and the five additional weights (50, 77, 100, 150 and 177 g), the experimental data obtained were subjected to regression analysis in the MS Office Excel program, using Velon's relationship (h = a∙ln(t) + b). The regression curves were analysed comparatively in order to identify possible differences and to highlight the variation of the penetration depth h, in relation to the time t. Based on the penetration depth between two-time intervals (every 5 seconds), the curves of variation of the penetration speed in relation to time were then drawn. It was found that Velon's law verifies the experimental data for all assortments of biscuits and for all five additional weights. The correlation coefficient R2 had in most of the analysed cases values over 0.850. The values recorded for the penetration depth were framed, in general, within 45-55 p.u. (penetrometric units) at an additional mass of 50 g, respectively between 155-168 p.u., at an additional mass of 177 g, at Petit Beurre biscuits. For Sultani diet biscuits, the values of the penetration depth were within the limits of 32-35 p.u., at an additional weight of 50 g and between 80-114 p.u., at an additional weight of 177g. The data presented in the paper can be used by both operators on the manufacturing technology flow, as well as by the traders of these food products, in order to establish the most efficient parametric of the working regimes (when packaging and handling).

Keywords: Biscuits resistance/texture, penetration depth, penetration velocity, sharp pin penetrometer.

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