Abstract: This work investigates upsetting of the tri-metallic cylindrical billets both experimentally and analytically with a reduction ratio 30%. Steel, brass, and copper are used for the outer and outmost rings and aluminum for the inner core. Two different models have been designed to show material flow and the cavity took place over the two interfaces during forming after this reduction ratio. Each model has an outmost ring material as steel. Model 1 has an outer ring between the outmost ring and the solid core material as copper and Model 2 has a material as brass. Solid core is aluminum for each model. Billets were upset in press machine by using parallel flat dies. Upsetting load was recorded and compared for models and single billets. To extend the tests and compare with experimental procedure to a wider range of inner core and outer ring geometries, finite element model was performed. ABAQUS software was used for the simulations. The aim is to show how contact between outmost ring, outer ring and the inner core are carried on throughout the upsetting process. Results have shown that, with changing in height, between outmost ring, outer ring and inner core, the Model 1 and Model 2 had very good interaction, and the contact surfaces of models had various interface behaviour. It is also observed that tri-metallic materials have lower weight but better mechanical properties than single materials. This can give an idea for using and producing these new materials for different purposes.
Abstract: Although gun barrel steels are an important variety from defense view point, available literatures are very limited. In the present work, an IF grade Ni-Cr-Mo-V high strength low alloy steel is produced in Electric Earth Furnace-ESR Route. Ingot was hot forged to desired dimension with a reduction ratio of 70-75% followed by homogenization, hardening and tempering treatment. Sample chemistry, NMIR, macro and micro structural analyses were done. Mechanical properties which include tensile, impact, and fracture toughness were studied. Ultrasonic testing was done to identify internal flaws. The existing high strength low alloy Ni-Cr-Mo-V steel shows improved properties in modified processing route and heat treatment schedule in comparison to properties noted earlier for manufacturing of gun barrels. The improvement in properties seems to withstand higher explosive loads with the same amount of steel in gun barrel application.
Abstract: Iron oxides are the main input to produce iron in integrated iron and steel plants. During production of iron from iron oxides, some wastes with high iron content occur. These main wastes can be classified as basic oxygen furnace (BOF) sludge, flue dust and rolling scale. Recycling of these wastes has a great importance for both environmental effects and reduction of production costs. In this study, recycling experiments were performed on basic oxygen furnace sludge, flue dust and rolling scale which contain 53.8%, 54.3% and 70.2% iron respectively. These wastes were mixed together with coke as reducer and these mixtures are pressed to obtain cylindrical briquettes. These briquettes were pressed under various compacting forces from 1 ton to 6 tons. Also, both stoichiometric and twice the stoichiometric cokes were added to investigate effect of coke amount on reduction properties of the waste mixtures. Then, these briquettes were reduced at 1000°C and 1100°C during 30, 60, 90, 120 and 150 min in a muffle furnace. According to the results of reduction experiments, the effect of compacting force, temperature and time on reduction ratio of the wastes were determined. It is found that 1 ton compacting force, 150 min reduction time and 1100°C are the optimum conditions to obtain reduction ratio higher than 75%.
Abstract: Optimisation of the physical and mechanical properties of cold rolled thin strips is achieved by controlling the rolling parameters. In this paper, the factors affecting the asymmetrical cold rolling of thin low carbon steel strip have been studied at a speed ratio of 1.1 without lubricant applied. The effect of rolling parameters on the resulting microstructure was also investigated. It was found that under dry condition, work roll shifting and work roll cross angle can improve the strip profile, and the result is more significant with an increase of work roll cross angle rather than that of work roll shifting. However, there was no obvious change in microstructure. In addition, effects of rolling parameters on strip profile and microstructure have also been discussed.
Abstract: Microstructure and mechanical properties of AZ91D
Mg alloys for nonflammable use, containing Ca and Y, were
investigated in this study. Solid solution treatment of AZ91D Mg alloy
with Ca and Y was successfully conducted at 420oC and
supersaturated microstructure with almost all beta phases resolved into
matrix was obtained. After solid solution treatment, the alloy was
annealed at temperatures of 180 and 200oC for time intervals from 1
min to 48 hrs and hardness of each condition was measured by
micro-Vickers method. Peak aging conditions were deduced from the
results as at the temperature of 200oC for 10 hrs. Hot rolling was also
carried out at 400oC by the reduction ratio of 0.6 through 5 passes
followed by recrystallization treatment. Tensile and compressive
properties were measured at room temperature on the specimens of
each process, i.e. as-cast, solution treatment, hot rolling, and
recrystallization.
Abstract: The present study was carried out to investigate the
effect of alloying elements and thermo-mechanical treatment (TMT)
i.e. hot rolling and forging with different reduction ratios on the
hardness (HV) and impact toughness (J) of heat-treated low alloy
steels. An understanding of the combined effect of TMT and alloying
elements and by measuring hardness, impact toughness, resulting
from different heat treatment following TMT of the low alloy steels,
it is possible to determine which conditions yielded optimum
mechanical properties and high strength to weight ratio.
Experimental Correlations between hot work reduction ratio,
hardness and impact toughness for thermo-mechanically heat treated
low alloy steels are analyzed quantitatively, and both regression and
mathematical hardness and impact toughness models are developed.
Abstract: Spheroidization heat treatment was conducted on the SK85 high carbon steel sheets with various initial microstructures obtained after cold rolling by various reduction ratios at a couple of annealing temperatures. On the high carbon steel sheet with fine pearlite microstructure, obtained by soaking at 800oC for 2hr in a box furnace and then annealing at 570oC for 5min in a salt bath furnace followed by water quenching, cold rolling was conducted by reduction ratios of 20, 30, and 40%. Heat treatment for spheroidization was carried out at 600 and 720oC for the various time intervals from 0.1 to 32 hrs. Area fraction of spheroidized cementite was measured with an image analyzer as a function of cold reduction ratios and duration times. Tensile tests were carried out at room temperature on the spheoidized high carbon steel.
Abstract: Recycling of aluminum beverage cans is an important issue due to its economic and environmental effect. One of the significant factors in aluminum cans recycling process is the transportation cost from the landfill space. An automatic compression baler (ACB) machine has been designed and built to densify the aluminum beverage cans. It has been constructed using numerous fabricated components. Two types of control methodology have been introduced in this ACB machine to achieve its goal. The first is a semi-automatic system, and the second is a mechatronic system by using a Programmable Logic Control (PLC). The effect of single and double pre-compression for the beverage cans have been evaluated by using the PLC control. Comparisons have been performed between the two types of control methodologies by operating this ACB machine in different working conditions. The double pre-compression in PLC control proves that there is an enhancement in the ACB performance by 133% greater than the direct compression in the semi-automatic control. In addition, the percentage of the reduction ratio in volume reaches 77%, and the compaction ratio reaches about four times of the initial volume.
Abstract: This paper has examined the energy consumption characteristics in six different buildings including apartments, offices, commercial buildings, hospitals, hotels and educational facilities. Then 5-hectare (50000m2) development site for respective building-s type has been assumed as case study to evaluate the introduction effect of Combined Heat and Power (CHP). All kinds of CHP systems with different distributed generation technologies including Gas Turbine (GT), Gas Engine (GE), Diesel Engine (DE), Solid Oxide Fuel Cell (SOFC) and Polymer Electrolyte Fuel Cell (PEFC), have been simulated by using HEATMAP, CHP system analysis software. And their primary energy utilization efficiency, energy saving ratio and CO2 reduction ratio have evaluated and compared respectively. The results can be summarized as follows: Various buildings have their special heat to power ratio characteristics. Matching the heat to power ratio demanded from an individual building with that supplied from a CHP system is very important. It is necessary to select a reasonable distributed generation technologies according to the load characteristics of various buildings. Distributed generation technologies with high energy generating efficiency and low heat to power ratio, like SOFC and PEFC is more reasonable selection for Building Combined Heat and Power (BCHP). CHP system is an attractive option for hotels, hospitals and apartments in Japan. The users can achieve high energy saving and environmental benefit by introducing a CHP systems. In others buildings, especially like commercial buildings and offices, the introduction of CHP system is unreasonable.
Abstract: This work presents a numerical model developed to
simulate the dynamics and vibrations of a multistage tractor gearbox.
The effect of time varying mesh stiffness, time varying frictional
torque on the gear teeth, lateral and torsional flexibility of the shafts
and flexibility of the bearings were included in the model. The model
was developed by using the Lagrangian method, and it was applied to
study the effect of three design variables on the vibration and stress
levels on the gears. The first design variable, module, had little effect
on the vibration levels but a higher module resulted to higher bending
stress levels. The second design variable, pressure angle, had little
effect on the vibration levels, but had a strong effect on the stress
levels on the pinion of a high reduction ratio gear pair. A pressure
angle of 25o resulted to lower stress levels for a pinion with 14 teeth
than a pressure angle of 20o. The third design variable, contact ratio,
had a very strong effect on both the vibration levels and bending
stress levels. Increasing the contact ratio to 2.0 reduced both the
vibration levels and bending stress levels significantly. For the gear
train design used in this study, a module of 2.5 and contact ratio of
2.0 for the various meshes was found to yield the best combination
of low vibration levels and low bending stresses. The model can
therefore be used as a tool for obtaining the optimum gear design
parameters for a given multistage spur gear train.