A design-for-casting integrated approach based on rapid simulation and modulus criterion

This paper presents a new approach to the design of cast components and their associated tools. The current methodology is analysed through a case study and its main disadvantages underlined. Then, in order to overcome these identified drawbacks, a new approach is proposed. Knowing that this approach is mainly based on a rapid simulation of the process, basics of a simplified physical model of solidification are presented as well as an associated modulus criterion. Finally, technical matters for a software prototype regarding the implementation of this Rapid Simulation Approach (RSA) in a CAD environment are detailed

Valve recession: From experiment to predictive model

Increasing demands on engine performance and cost reductions have meant that advances made in materials and production technology are often outpaced This frequently results in wear problems occurring with engine components. Few models exist for predicting wear, and consequently each wear problem has to be investigated, the cause isolated and remedial action taken. The objective of this work was to carry out experimental studies to investigate valve and seat insert wear mechanisms and use the test results to develop a recession prediction tool to assess the potential for valve recession and solve problems that occur more quickly. Experimental apparatus has been developed that is capable of providing a valid simulation of the wear of diesel automotive inlet valves and seats. Test methodologies developed have isolated the effects of impact and sliding. A semi-empirical wear model for predicting valve recession has been developed based on data gathered during the bench testing. A software program, RECESS, was developed to run the model. Model predictions are compared with engine dynamometer tests and bench tests. The model can be used to give a quantitative prediction of the valve recession to be expected with a particular material pair or a qualitative assessment of how parameters need to be altered in order to reduce recession. The valve recession model can be integrated into an industrial environment in order to help reduce costs and timescales involved in solving valve/seat wear problems

INEL Spray-forming Research

Spray forming is a near-net-shape fabrication technology in which a spray of finely atomized liquid droplets is deposited onto a suitably shaped substrate or mold to produce a coherent solid. The technology offers unique opportunities for simplifying materials processing without sacrificing, and oftentimes substantially improving, product quality. Spray forming can be performed with a wide range of metals and nonmetals, and offers property improvements resulting from rapid solidification (e.g., refined microstructures, extended solid solubilities and reduced segregation). Economic benefits result from process simplification and the elimination of unit operations. Researchers at the Idaho National Engineering Laboratory (INEL) are developing spray-forming technology for producing near-net-shape solids and coatings of a variety of metals, polymers, and composite materials. Results from several spray forming programs are presented to illustrate the range of capabilities of the technique as well as the accompanying technical and economic benefits. Low-carbon steel strip greater than 0.75 mm thick and polymer membranes for gas/gas and liquid/liquid separations that were spray formed are discussed; recent advances in spray forming molds, dies, and other tooling using low-melting-point metals are described

Prospects for large-scale financial systems simulation

As the 21st century unfolds, we find ourselves having to control, support, manage or otherwise cope with large-scale complex adaptive systems to an extent that is unprecedented in human history. Whether we are concerned with issues of food security, infrastructural resilience, climate change, health care, web science, security, or financial stability, we face problems that combine scale, connectivity, adaptive dynamics, and criticality. Complex systems simulation is emerging as the key scientific tool for dealing with such complex adaptive systems. Although a relatively new paradigm, it is one that has already established a track record in fields as varied as ecology (Grimm and Railsback, 2005), transport (Nagel et al., 1999), neuroscience (Markram, 2006), and ICT (Bullock and Cliff, 2004). In this report, we consider the application of simulation methodologies to financial systems, assessing the prospects for continued progress in this line of research

Non-linear 3D finite element analysis of the anchorage zones of pretensioned concrete girders and experimental verification

This paper focuses on the modelling of the anchorage zone of a pretensioned girder. The finite element software Abaqus was used to create a 3D non-linear finite element model (FEM). This analysis was performed on a full-scale pretensioned girder with end blocks and with various types of strand modelling, where accurate contact properties between prestressing steel and concrete are essential. The model has been validated by comparing the numerical strain results with the strain measurements on a full-scale girder with end blocks, which was produced in a precast concrete plant. At the same time, a parametric study was executed to determine the value of the coefficient of friction between the strands and the concrete and to examine the sensitivity of the input parameters of the model. The results have indicated that an accurate determination of the concrete properties at the time of release is very important. Furthermore, the Hoyer effect is analysed. It is found that the radial expansion of the strand in the finite element model is in good agreement with the theoretically calculated expansion of the strand which demonstrates the accuracy of the finite element model. In addition, it is shown that the Hoyer effect influences the force transfer of two adjacent strands. The aim of this research is to investigate the potential of an alternative FE model of a pretensioned girder based on strand to concrete frictional behaviour, rather than the commonly used models based on an assumed shear stress distribution along the transfer length

A dynamics-driven approach to precision machines design for micro-manufacturing and its implementation perspectives

Precision machines are essential elements in fabricating high quality micro products or micro features and directly affect the machining accuracy, repeatability and efficiency. There are a number of literatures on the design of industrial machine elements and a couple of precision machines commercially available. However, few researchers have systematically addressed the design of precision machines from the dynamics point of view. In this paper, the design issues of precision machines are presented with particular emphasis on the dynamics aspects as the major factors affecting the performance of the precision machines and machining processes. This paper begins with a brief review of the design principles of precision machines with emphasis on machining dynamics. Then design processes of precision machines are discussed, and followed by a practical modelling and simulation approaches. Two case studies are provided including the design and analysis of a fast tool servo system and a 5-axis bench-top micro-milling machine respectively. The design and analysis used in the two case studies are formulated based on the design methodology and guidelines