Dimpling process in cold roll metal forming by finite element modelling and experimental validation

The dimpling process is a novel cold-roll forming process that involves dimpling of a rolled flat strip prior to the roll forming operation. This is a process undertaken to enhance the material properties and subsequent products’ structural performance while maintaining a minimum strip thickness. In order to understand the complex and interrelated nonlinear changes in contact, geometry and material properties that occur in the process, it is necessary to accurately simulate the process and validate through physical tests. In this paper, 3D non-linear finite element analysis was employed to simulate the dimpling process and mechanical testing of the subsequent dimpled sheets, in which the dimple geometry and material properties data were directly transferred from the dimpling process. Physical measurements, tensile and bending tests on dimpled sheet steel were conducted to evaluate the simulation results. Simulation of the dimpling process identified the amount of non-uniform plastic strain introduced and the manner in which this was distributed through the sheet. The plastic strain resulted in strain hardening which could correlate to the increase in the strength of the dimpled steel when compared to plain steel originating from the same coil material. A parametric study revealed that the amount of plastic strain depends upon on the process parameters such as friction and overlapping gap between the two forming rolls. The results derived from simulations of the tensile and bending tests were in good agreement with the experimental ones. The validation indicates that the finite element analysis was able to successfully simulate the dimpling process and mechanical properties of the subsequent dimpled steel products

Molecular systematics and phylogenetics of the spider genus Mastigusa Menge, 1854 (Araneae, Cybaeidae)

The palearctic spider genus Mastigusa Menge, 1854 is characterized by a remarkable morphology and wide ecological variability, with free-living, cave dwelling and myrmecophile populations known. This genus has a long and tangled taxonomic history and was placed in different families in the past, all belonging to the “marronoid clade”, an informal grouping of families characterized by the lack of strong synapomorphies. Three species are currently recognized, but their identity and circumscription has been long debated. A molecular approach was never applied for trying to solve these uncertainties, and doubts still remain both about its phylogenetic placement and about the taxonomic status of the described species. For the first time the genus Mastigusa is included in a molecular phylogenetic analysis and strong support is found for its placement within the family Cybaeidae, in sister relationship with the genus Cryphoeca Thorell, 1870. An analysis of Mastigusa populations spanning across the distribution range of the genus identifies a high and previously overlooked genetic diversity, with six distinct genetic lineages showing a strong geographic pattern. Divergence times between Mastigusa and its sister genus and between the distinct Mastigusa lineages are estimated, and the groundwork is laid for a taxonomic revision of the species belonging to the genus

Exploring mitogenome evolution in Branchiopoda (Crustacea) lineages reveals gene order rearrangements in Cladocera

The class Branchiopoda, whose origin dates back to Cambrian, includes ~ 1200 species which mainly occupy freshwater habitats. The phylogeny and systematics of the class have been debated for long time, until recent phylogenomic analyses allowed to better clarify the relationships among major clades. Based on these data, the clade Anostraca (fairy and brine shrimps) is sister to all other branchiopods, and the Notostraca (tadpole shrimps) results as sister group to Diplostraca, which includes Laevicaudata + Spinicaudata (clam shrimps) and Cladoceromorpha (water fleas + Cyclestherida). In the present analysis, thanks to an increased taxon sampling, a complex picture emerges. Most of the analyzed mitogenomes show the Pancrustacea gene order while in several other taxa they are found rearranged. These rearrangements, though, occur unevenly among taxa, most of them being found in Cladocera, and their taxonomic distribution does not agree with the phylogeny. Our data also seems to suggest the possibility of potentially homoplastic, alternative gene order within Daphniidae

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New association between red wood ant species (Formica rufa group) and the myrmecophilic spiders Mastigusa arietina and Thyreosthenius biovatus

Ants belonging to the Formica rufa species group, counting 10 representatives in Europe, are often referred to as red wood ants (RWAs). These dominant, mound building species are known to host in their nests an extremely diverse fauna of associated myrmecophilic arthropods, among which are the two W-Palaearctic spider species Mastigusa arietina (Thorell 1871) and Thyreosthenius biovatus (O. Pickard-Cambridge 1875). The actual host range of these spiders within the Formica rufa group is little known, due to the taxonomic uncertainties that have characterized RWAs in the past. We conducted a large-scale survey for assessing the occurrence of both spider species in association with different RWAs, with a focus on an accurate identification of the ant species. We recorded co-occurrence data for 5 European representatives of the Formica rufa group, and we reported for the first time on the co-occurrence of M. arietina with Formica aquilonia Yarrow 1955, Formica lugubris Zetterstedt 1838 and Formica paralugubris Seifert 1996, and of T. biovatus with F. aquilonia. We found no association between the rate of presence/absence of the two spiders and host ant species or sampling localities, which suggests a non-selective exploitation of RWA hosts by the two myrmecophilic spiders

Down-Hole Heat Exchangers: Modelling of a Low-Enthalpy Geothermal System for District Heating

In order to face the growing energy demands, renewable energy sources can provide an alternative to fossil fuels. Thus, low-enthalpy geothermal plants may play a fundamental role in those areas—such as the Province of Viterbo—where shallow groundwater basins occur and conventional geothermal plants cannot be developed. This may lead to being fuelled by locally available sources. The aim of the present paper is to exploit the heat coming from a low-enthalpy geothermal system. The experimental plant consists in a down-hole heat exchanger for civil purposes and can supply thermal needs by district heating. An implementation in MATLAB environment is provided in order to develop a mathematical model. As a consequence, the amount of withdrawable heat can be successfully calculated

Finite Element Analysis of Cold-Formed Dimpled Steel Columns

Dimpled steel products are produced from the combination of an innovative dimpling process and a traditional forming process such as cold-roll forming or press-braking. The wider use of cold-formed dimpled steel members has promoted considerable interest in the local instability and strength of these members. Of particular interest is their buckling behaviour and ultimate strength capacity. However, the dimpling process produces cold-formed sections with a complex ‘dimpled’ surface topography and the ‘dimpled’ material is nonuniformly work hardened through the entire thickness. Owing to these complex issues, there are no existing methods to calculate the buckling strength of the dimpled products and validate against physical measurements. This paper presents a Finite Element analysis of the compressive behaviour of cold-formed dimpled steel columns. True stress-strain data obtained from physical tests were incorporated into nonlinear simulations of dimpled steel columns. The simulation results were compared with compression test results on dimpled channel and lipped channel columns and good agreements in both buckling and ultimate strength were obtained. It is demonstrated that the Finite Element analysis can therefore be used to analyse and design cold-formed dimpled steel columns

Acoustic Performance of Different Cold-Formed Studs in Double-Leaf Walls by Finite Element Analysis and Experiment

Cold-formed steel studs are often used in lightweight partition walls to provide structural stability but in the same time they change the acoustic performance of the whole system. The overall design of such lightweight structures for acoustic sound insulation becomes very complicated as the sound passing through stud needs to be quantified. One of the greatest challenges is to characterise the stud’s geometric effects on the sound transmission of the partition walls. This paper presents a Finite Element modelling approach and results into the acoustic performance of cold-formed studs in double-leaf walls which are placed in between a source room and a receiving room. The acoustic medium was modelled using fluid elements and the structure was modelled with conventional stress elements. The interaction between the acoustic medium and the structure was modelled in a coupled structural-acoustic analysis. An FE modelling setup which includes appropriate model parameters to be used in the structural-acoustic analysis was presented. The FE sound transmission loss of double-leaf walls using two different stud profiles was then calculated. Experimental tests complying with BS EN Standards 717 and 140 were also carried out to evaluate the FE results. It has shown that the FE results have similar trends and are in fair agreement with the experimental results; and the stud’s shape has significant effects on the sound transmission of the double-leaf walls. The FE analysis is a powerful tool and can be used as a complementary and alternative method to the laboratory tests for acoustic performance of double-leaf walls with steel studs

The Design and Development of New Cold Roll Formed Products by Finite Element Modeling and Optimisation

The design and development of new cold roll formed products can incur significant cost and the product may not be optimised for either performance or manufacture. This paper describes a new method to develop an optimum structural design of profile by cold roll forming using a combined approach of finite element analysis and optimisation techniques. To illustrate the concept, the design and development of a new channel beam and a new drain grating subjected to bending are presented. The two case studies, demonstrate how a roll formed profile may be optimised to improved structural performance through use of stiffeners and/or dimples. Improved performance of cold roll formed products is achieved by increasing the strength of the product without increasing the amount of the material used. The results of this paper clearly demonstrate an efficient and effective method and tool set to optimise design for performance and manufacture of cold roll formed products