Abstract: Forming processes induce residual deformations on the reinforcement and sometimes lead to mesoscopic defects, which are more recurrent than macroscopic defects during the manufacture of complex structural parts. This study deals with the influence of the fabric shear and buckles defects, which appear during draping processes of composite, on the impact behavior of a glass fiber reinforced polymer. To achieve this aim, we produced several specimens with different amplitude of deformations (shear) and defects on the fabric using a specific bench. The specimens were manufactured using the contact molding and tested with several impact energies. The results and measurements made on tested specimens were compared to those of the healthy material. The results showed that the buckle defects have a negative effect on elastic parameters and revealed a larger damage with significant out-of-plane mode relatively to the healthy composite material. This effect is the consequence of a local fiber impoverishment and a disorganization of the fibrous network, with a reorientation of the fibers following the out-of-plane buckling of the yarns, in the area where the defects are located. For the material with calibrated shear of the reinforcement, the increased local fiber rate due to the shear deformations and the contribution to stiffness of the transverse yarns led to an increase in mechanical properties.
Abstract: Eventually train accidents occur on railways and for some specific cases it is necessary to use a train rescue with a crane positioned under a platform wagon. These tumbled machines are collected and sent to the machine shop or scrap yard. In one of these cranes that were being used to rescue a wagon, occurred a fall of hoist due to fracture of two large pins. The two pins were collected and sent for failure analysis. This work investigates the main cause and the secondary causes for the initiation of the fatigue crack. All standard failure analysis procedures were applied, with careful evaluation of the characteristics of the material, fractured surfaces and, mainly, metallographic tests using an optical microscope to compare the geometry of the peaks and valleys of the thread of the pins and their respective seats. By metallographic analysis, it was concluded that the fatigue cracks were started from a notch (stress concentration) in the valley of the threads of the pin applied to the right side of the crane (pin 1). In this, it was verified that the peaks of the threads of the pin seat did not have proper geometry, with sharp edges being present that caused such notches. The visual analysis showed that fracture of the pin on the left side of the crane (pin 2) was brittle type, being a consequence of the fracture of the first one. Recommendations for this and other railway cranes have been made, such as nondestructive testing, stress calculation, design review, quality control and suitability of the mechanical forming process of the seat threads and pin threads.
Abstract: This paper considers a forming process of a single competitive factor in the digital camera industry from the viewpoint of product platform. To make product development easier for companies and to increase product introduction ratios, development efforts concentrate on improving and strengthening certain product attributes, and it is born in the process that the product platform is formed continuously. It is pointed out that the formation of this product platform raises product development efficiency of individual companies, but on the other hand, it has a trade-off relationship of causing unification of competitive factors in the whole industry. This research tries to analyze product specification data which were collected from the web page of digital camera companies. Specifically, this research collected all product specification data released in Japan from 1995 to 2003 and analyzed the composition of image sensor and optical lens; and it identified product platforms shared by multiple products and discussed their application. As a result, this research found that the product platformation was born in the development of the standard product for major market segmentation. Every major company has made product platforms of image sensors and optical lenses, and as a result, this research found that the competitive factors were unified in the entire industry throughout product platformation. In other words, this product platformation brought product development efficiency of individual firms; however, it also caused industrial competition factors to be unified in the industry.
Abstract: The paper presents a methodology for real-time structural health monitoring and geophysical applications. The key elements of the system are a high performance MIMO RADAR sensor, an optical camera and a dedicated set of software algorithms encompassing interferometry, tomography and photogrammetry. The MIMO Radar sensor proposed in this work, provides an extremely high sensitivity to displacements making the system able to react to tiny deformations (up to tens of microns) with a time scale which spans from milliseconds to hours. The MIMO feature of the system makes the system capable of providing a set of two-dimensional images of the observed scene, each mapped on the azimuth-range directions with noticeably resolution in both the dimensions and with an outstanding repetition rate. The back-scattered energy, which is distributed in the 3D space, is projected on a 2D plane, where each pixel has as coordinates the Line-Of-Sight distance and the cross-range azimuthal angle. At the same time, the high performing processing unit allows to sense the observed scene with remarkable refresh periods (up to milliseconds), thus opening the way for combined static and dynamic structural health monitoring. Thanks to the smart TX/RX antenna array layout, the MIMO data can be processed through a tomographic approach to reconstruct the three-dimensional map of the observed scene. This 3D point cloud is then accurately mapped on a 2D digital optical image through photogrammetric techniques, allowing for easy and straightforward interpretations of the measurements. Once the three-dimensional image is reconstructed, a 'repeat-pass' interferometric approach is exploited to provide the user of the system with high frequency three-dimensional motion/vibration estimation of each point of the reconstructed image. At this stage, the methodology leverages consolidated atmospheric correction algorithms to provide reliable displacement and vibration measurements.
Abstract: Carbon dioxide and methane, the major components of biomass pyrolysis/gasification gas and biogas, top the list of substances that cause climate change, but they are also among the most important renewable energy sources in modern society. The purpose of this study is to convert carbon dioxide and methane into high-quality energy using char and commercial activated carbon obtained from biomass pyrolysis as a microwave receptor. The methane reforming process produces hydrogen and carbon. This carbon is deposited in the pores of the microwave receptor and lowers catalytic activity, thereby reducing the methane conversion rate. The deposited carbon was removed by carbon gasification due to the supply of carbon dioxide, which solved the problem of microwave receptor inactivity. In particular, the conversion rate remained stable at over 90% when the ratio of carbon dioxide to methane was 1:1. When the reforming results of carbon dioxide and methane were compared after fabricating nickel and iron catalysts using commercial activated carbon as a carrier, the conversion rate was higher in the iron catalyst than in the nickel catalyst and when no catalyst was used.
Abstract: Laser Forming process as a non-contact thermal forming process is widely used to forming and bending of metallic and non-metallic sheets. In this process, according to laser irradiation along a specific path, sheet is bent. One of the most important output parameters in laser forming is bending angle that depends on process parameters such as physical and mechanical properties of materials, laser power, laser travel speed and the number of scan passes. In this paper, Artificial Neural Network and Fuzzy Logic System were used to predict of bending angle in laser forming process. Inputs to these models were laser travel speed and laser power. The comparison between artificial neural network and fuzzy logic models with experimental results has been shown both of these models have high ability to prediction of bending angles with minimum errors.
Abstract: Earing defect in drawing process is highly undesirable not only because it adds on an additional trimming operation but also because the uneven material flow demands extra care. The objective of this work is to study the earing problem in the Deep Drawing of circular cup and to optimize the blank shape to reduce the earing. A finite element model is developed for 3-D numerical simulation of cup forming process in ABAQUS. Extra-deep-drawing (EDD) steel sheet has been used for simulation. Properties and tool design parameters were used as input for simulation. Earing was observed in the simulated cup and it was measured at various angles with respect to rolling direction. To reduce the earing defect initial blank shape was modified with the help of anisotropy coefficient. Modified blanks showed notable reduction in earing.
Abstract: The numerical simulation based on the Finite Element Method (FEM) is widely used in academic institutes and in the industry. It is a useful tool to predict many phenomena present in the classical manufacturing forming processes such as fracture. But, the results of such numerical model depend strongly on the parameters of the constitutive behavior model. The influences of thermal and mechanical loads cause damage. The temperature and strain rate dependent materials’ properties and their modelling are discussed. A Johnson-Cook Model of damage has been selected for the numerical simulations. Virtual software called the ABAQUS 6.11 is used for finite element analysis. This model was introduced in order to give information concerning crack initiation during thermal and mechanical loads.
Abstract: In order to predict and model wrinkling which is caused by out of plane deformation due to compressive loading in the plane of the material during composite prepregs forming, it is necessary to quantitatively understand the relative magnitude of the bending stiffness. This study aims to examine the bending properties of out-of-autoclave (OOA) thermosetting prepreg under vertical cantilever test condition. A direct method for characterizing the bending behavior of composite prepregs was developed. The results from direct measurement were compared with results derived from an image-processing procedure that analyses the captured image during the vertical bending test. A numerical simulation was performed using ABAQUS to confirm the bending stiffness value.
Abstract: There is not much effective guideline on development of design parameters selection on spring back for advanced high strength steel sheet metal in U-channel process during cold forming process. This paper presents the development of predictive model for spring back in U-channel process on advanced high strength steel sheet employing Response Surface Methodology (RSM). The experimental was performed on dual phase steel sheet, DP590 in Uchannel forming process while design of experiment (DoE) approach was used to investigates the effects of four factors namely blank holder force (BHF), clearance (C) and punch travel (Tp) and rolling direction (R) were used as input parameters using two level values by applying Full Factorial design (24 ). From a statistical analysis of variant (ANOVA), result showed that blank holder force (BHF), clearance (C) and punch travel (Tp) displayed significant effect on spring back of flange angle (β2 ) and wall opening angle (β1 ), while rolling direction (R) factor is insignificant. The significant parameters are optimized in order to reduce the spring back behavior using Central Composite Design (CCD) in RSM and the optimum parameters were determined. A regression model for spring back was developed. The effect of individual parameters and their response was also evaluated. The results obtained from optimum model are in agreement with the experimental values.
Abstract: Vancron 40, a nitrided powder metallurgical tool
Steel, is used in cold work applications where the predominant failure
mechanisms are adhesive wear or galling. Typical applications of
Vancron 40 are among others fine blanking, cold extrusion, deep
drawing and cold work rolls for cluster mills. Vancron 40 positive
results for cold work rolls for cluster mills and as a tool for some
severe metal forming process makes it competitive compared to other
type of work rolls that require higher precision, among others in cold
rolling of thin stainless steel, which required high surface finish
quality. In this project, three roll materials for cold rolling of stainless
steel strip was examined, Vancron 40, Narva 12B (a high-carbon,
high-chromium tool steel alloyed with tungsten) and Supra 3 (a
Chromium-molybdenum tungsten-vanadium alloyed high speed
steel). The purpose of this project was to study the depth profiles of
the ironed stainless steel strips, emergence of galling and to study the
lubrication performance used by steel industries. Laboratory
experiments were conducted to examine scratch of the strip, galling
and surface roughness of the roll materials under severe tribological
conditions. The critical sliding length for onset of galling was
estimated for stainless steel with four different lubricants. Laboratory
experiments result of performance evaluation of resistance capability
of rolls toward adhesive wear under severe conditions for low and
high reductions. Vancron 40 in combination with cold rolling
lubricant gave good surface quality, prevents galling of
metal surfaces and good bearing capacity.
Abstract: In sheet metal forming process, raw material
mechanical properties are important parameters. This paper is to
compare the wall’s incline angle or formability of SS 400 steel and
SUS 304 stainless steel in single point incremental forming. The two
materials are ferrous base alloyed, which have the different unit cell,
mechanical property and chemical composition. They were forming
into cone shape specimens having 100 mm diameter with different
wall’s incline angle: 90o, 75o and 60o. The investigation was
continued until the specimens formed surface facture. The
experimental result showed that the smaller the wall incline angle
higher the formability with the both materials. The formability limit
of the ferrous base alloy was approx. 60o wall’s incline angle. By
nature, SS 400 has higher formability than SUS 304. This result can
be used as the initial data in designing the single point incremental
forming parts.
Abstract: With demand for primary energy continuously
growing, search for renewable and efficient energy sources has been
high on agenda of our society. One of the most promising energy
sources is biogas technology. Residues coming from dairy industry
and milk processing could be used in biogas production; however,
low efficiency and high cost impede wide application of such
technology. One of the main problems is management and conversion
of organic residues through the anaerobic digestion process which is
characterized by acidic environment due to the low whey pH (
Abstract: Flow forming is widely used in many industries, especially in defence technology industries. Pressure vessels requirements are high precision, light weight, seamless and optimum strength. For large pressure vessels, flow forming by 3 rollers machine were used. In case of long range rocket motor case flow forming and welding of pressure vessels have been used for manufacturing. Due to complication of welding process, researchers had developed 4 meters length pressure vessels without weldment by 4 rollers flow forming machine. Design and preparation of preform work pieces are performed. The optimization of flow forming parameter such as feed rate, spindle speed and depth of cut will be discussed. The experimental result shown relation of flow forming parameters to quality of flow formed tube and prototype pressure vessels have been made.
Abstract: The design of multi stage deep drawing processes requires the evaluation of many process parameters such as the intermediate die geometry, the blank shape, the sheet thickness, the blank holder force, friction, lubrication etc..These process parameters have to be determined for the optimum forming conditions before the process design. In general sheet metal forming may involve stretching drawing or various combinations of these basic modes of deformation. It is important to determine the influence of the process variables in the design of sheet metal working process. Especially, the punch and die corner for deep drawing will affect the formability. At the same time the prediction of sheet metals springback after deep drawing is an important issue to solve for the control of manufacturing processes. Nowadays, the importance of this problem increases because of the use of steel sheeting with high stress and also aluminum alloys.
The aim of this paper is to give a better understanding of the springback and its effect in various sheet metals forming process such as expansion and restreint deep drawing in the cup drawing process, by varying radius die, lubricant for two commercially available materials e.g. galvanized steel and Aluminum sheet. To achieve these goals experiments were carried out and compared with other results. The original of our purpose consist on tests which are ensured by adapting a U-type stretching-bending device on a tensile testing machine, where we studied and quantified the variation of the springback.
Abstract: Materials with ultrafine-grained structure and unique physical and mechanical properties can be obtained by methods of severe plastic deformation, which include processes of asymmetric rolling (AR). Asymmetric rolling is a very effective way to create ultrafine-grained structures of metals and alloys. Since the asymmetric rolling is a continuous process, it has great potential for industrial production of ultrafine-grained structure sheets. Basic principles of asymmetric rolling are described in detail in scientific literature. In this work finite element modeling of asymmetric rolling and metal forming processes in multiroll gauge was performed. Parameters of the processes which allow achieving significant values of shear strain were defined. The results of the study will be useful for the research of the evolution of ultra-fine metal structure in asymmetric rolling.
Abstract: A large part of Russia is located in permafrost areas. These areas are widely used because there are concentrated valuable natural resources. Therefore to explore of cryosols it is important due to the significant increase of anthropogenic stress as well as the problem of global climate change. In the north of Western Siberia permafrost phenomena is widespread. Permafrost as a factor of soil formation and cryogenesis as a process have a great impact on the soil formation of these areas. Based on the research results of permafrost-affected soils tundra landscapes formed in the central part of the Tazovskiy Peninsula in cryogenic conditions, data were obtained which characterize the morphological features of soils. The specificity of soil cover distribution and manifestation of soil-forming processes within the study area are noted. Permafrost features such as frost cracking, cryoturbation, thixotropy, movement of humus are formed. The formation of these features is increased with the development of the territory. As a consequence, there is a change in the components of the environment and the destruction of the soil cover.
Abstract: The paper analyzes the response of buildings and industrially structures on seismic waves (low frequency mechanical vibration) generated by blasting operations. The principles of seismic analysis can be applied for different kinds of excitation such as: earthquakes, wind, explosions, random excitation from local transportation, periodic excitation from large rotating and/or machines with reciprocating motion, metal forming processes such as forging, shearing and stamping, chemical reactions, construction and earth moving work, and other strong deterministic and random energy sources caused by human activities. The article deals with the response of seismic, low frequency, mechanical vibrations generated by nearby blasting operations on a residential home. The goal was to determine the fundamental natural frequencies of the measured structure; therefore it is important to determine the resonant frequencies to design a suitable modal damping. The article also analyzes the package of seismic waves generated by blasting (Primary waves – P-waves and Secondary waves S-waves) and investigated the transfer regions. For the detection of seismic waves resulting from an explosion, the Fast Fourier Transform (FFT) and modal analysis, in the frequency domain, is used and the signal was acquired and analyzed also in the time domain. In the conclusions the measured results of seismic waves caused by blasting in a nearby quarry and its effect on a nearby structure (house) is analyzed. The response on the house, including the fundamental natural frequency and possible fatigue damage is also assessed.
Abstract: Oxyhydrogen is a mixture of Hydrogen (H2) and Oxygen (O2) gases. Detonative mixtures of oxyhydrogens with various combinations of these two gases were used in Gas Detonation Forming (GDF) to form sheets of mild steel. In die forming experiments, three types of conical dies with apex angles of 60, 90 and 120 degrees were used. Pressure of mixtures inside the chamber before detonation was varied from 3 Bar to 5 Bar to investigate the effect of pre-detonation pressure in the forming process. On each conical die, several experiments with different percentages of Hydrogen were carried out to determine the optimum gaseous mixture. According to our results the best forming process occurred when approximately 50-70%. Hydrogen was employed in the mixture. Furthermore, the experimental results were compared to the ones from FEM analysis. The FEM simulation results of thickness strain, hoop strain, thickness variation and deformed geometry are promising.
Abstract: The orthogonal processes to shape the triangle steel plate into a equilateral vertical steel are examined by an incremental elasto-plastic finite-element method based on an updated Lagrangian formulation. The highly non-linear problems due to the geometric changes, the inelastic constitutive behavior and the boundary conditions varied with deformation are taken into account in an incremental manner. On the contact boundary, a modified Coulomb friction mode is specially considered. A weighting factor r-minimum is employed to limit the step size of loading increment to linear relation. In particular, selective reduced integration was adopted to formulate the stiffness matrix. The simulated geometries of verticality could clearly demonstrate the vertical processes until unloading. A series of experiments and simulations were performed to validate the formulation in the theory, leading to the development of the computer codes. The whole deformation history and the distribution of stress, strain and thickness during the forming process were obtained by carefully considering the moving boundary condition in the finite-element method. Therefore, this modeling can be used for judging whether a equilateral vertical steel can be shaped successfully. The present work may be expected to improve the understanding of the formation of the equilateral vertical steel.