Aluminium extrusion analysis by the finite volume method

Present work proposes a novel numerical scheme to calculate stress and velocity fields of metal flow in axisymmetric extrusion process in steady state. Extrusion of aluminium is one main metal forming process largely applied in manufacturing bars and products with complex cross section shape. The upper-bound, slab, slip-line methods and more recently the numerical methods such as the Finite Element Method have been commonly applied in aluminium extrusion analysis. However, recently in the academy, the Finite Volume Method has been developed for metal flow analysis: literature suggests that extrusion of metals can be modelled by the flow formulation. Hence, metal flow can be mathematically modelled such us an incompressible non linear viscous fluid, owing to volume constancy and varying viscosity in metal forming. The governing equations were discretized by the Finite Volume Method, using the Explicit MacCormack Method in structured and collocated mesh. The MacCormack Method is commonly used to simulate compressible fluid flow by the finite volume method. However, metal plastic flow and incompressible fluid flow do not present state equations for the evolution of pressure, and therefore, a velocity-pressure coupling method is necessary to obtain a consistent velocity and pressure fields. The SIMPLE Method was applied to attain pressure-velocity coupling. This new numerical scheme was applied to forward hot extrusion process of an aluminium alloy. The metal extrusion velocity fields achieved fast convergence and a good agreement with experimental results. The MacCormack Method applied to metal extrusion produced consistent results without the need of artificial viscosity as employed by the compressible flow simulation approaches. Therefore, present numerical results also suggest that MacCormack method together with SIMPLE method can be applied in the solution of metal forming processes in addition to the traditional application for compressible fluid flow

Gearing

Gearing technology in its modern form has a history of only 100 years. However, the earliest form of gearing can probably be traced back to fourth century B.C. Greece. Current gear practice and recent advances in the technology are drawn together. The history of gearing is reviewed briefly in the Introduction. Subsequent sections describe types of gearing and their geometry, processing, and manufacture. Both conventional and more recent methods of determining gear stress and deflections are considered. The subjects of life prediction and lubrication are additions to the literature. New and more complete methods of power loss predictions as well as an optimum design of spur gear meshes are described. Conventional and new types of power transmission systems are presented

A novel approach towards a lubricant-free deep drawing process via macro-structured tools

In today’s industry, the sustainable use of raw materials and the development of new green technology in mass production, with the aim of saving resources, energy and production costs, is a significant challenge. Deep drawing as a widely used industrial sheet metal forming process for the production of automotive parts belongs to one of the most energy-efficient production techniques. However, one disadvantage of deep drawing regarding the realisation of green technology is the use of lubricants in this process. Therefore, a novel approach for modifying the conventional deep drawing process to achieve a lubricant-free deep drawing process is introduced within this thesis. In order to decrease the amount of frictional force for a given friction coefficient, the integral of the contact pressure over the contact area has to be reduced. To achieve that, the flange area of the tool is macro-structured, which has only line contacts. To avoid the wrinkling, the geometrical moment of inertia of the sheet should be increased by the alternating bending mechanism of the material in the flange area through immersing the blankholder slightly into the drawing die

Liquid rocket metal tanks and tank components

Significant guidelines are presented for the successful design of aerospace tanks and tank components, such as expulsion devices, standpipes, and baffles. The state of the art is reviewed, and the design criteria are presented along with recommended practices. Design monographs are listed

Impacts of Restructurings on Manufacturing Productive Efficiency: Evidence from China

This paper studies the effects of privatization and non-ownership-change reforms on firms’ productivity in China. As one of the most prominent empirical challenges in China privatization studies, endogeneity problems are addressed with a first-difference instrumental variable GMM estimation. We find that privatization does not improve firms’ productivity immediately. Instead, its effects become significantly positive in the year after conversion. In addition, partial privatization fails to lead to improved efficiency whereas insider privatization boosts firms’ productivity shortly after the first year of privatization but the effects quickly fade after two years of privatization. Lastly, all non-ownership-change reforms, except leasing, are proved to be ineffective even when issues like social burdens, worker redundancy, management incentives and soft-budget constraint are tackled before the restructuring.privatization, soft budget constraint, transition economies, Chinese economy

Quantifying Mechanical Properties of Automotive Steels with Deep Learning Based Computer Vision Algorithms

This paper demonstrates that the instrumented indentation test (IIT), together with a trained artificial neural network (ANN), has the capability to characterize the mechanical properties of the local parts of a welded steel structure such as a weld nugget or heat affected zone. Aside from force-indentation depth curves generated from the IIT, the profile of the indented surface deformed after the indentation test also has a strong correlation with the materials’ plastic behavior. The profile of the indented surface was used as the training dataset to design an ANN to determine the material parameters of the welded zones. The deformation of the indented surface in three dimensions shown in images were analyzed with the computer vision algorithms and the obtained data were employed to train the ANN for the characterization of the mechanical properties. Moreover, this method was applied to the images taken with a simple light microscope from the surface of a specimen. Therefore, it is possible to quantify the mechanical properties of the automotive steels with the four independent methods: (1) force-indentation depth curve; (2) profile of the indented surface; (3) analyzing of the 3D-measurement image; and (4) evaluation of the images taken by a simple light microscope. The results show that there is a very good agreement between the material parameters obtained from the trained ANN and the experimental uniaxial tensile test. The results present that the mechanical properties of an unknown steel can be determined by only analyzing the images taken from its surface after pushing a simple indenter into its surface

Fracture criteria for discontinuously reinforced metal matrix composites

Summarized is the progress achieved during the period September 16, 1987 to August 15, l988 on NASA Grant NAG1-724, Fracture Criteria for Discontinuously Reinforced Metal Matrix Composites. Appended are copies of three manuscripts prepared under NASA funding during the performance period