A numerical approach to robust in-line control of roll forming processes

The quality of roll formed products is known to be highly sensitive and dependent on the process parameters and thus the unavoidable variations of these parameters during mass production. To maintain a constant high product quality, a new roll former with an adjustable final roll forming stand is developed at Deakin University enabling the continuous compensation for possible shape defects. In this work, a numerical approach to robust in-line control of the roll forming of a V-section profile is presented, combining the aspects of robust process design and in-line compensation methods. A numerical study is performed to determine the relationship between controllable process settings and uncontrollable variation of incoming material properties with respect to the common product defects longitudinal bow and springback. The computationally expensive non-linear FE simulations used in this study are subsequently replaced by metamod-els based on efficient Single Response Surfaces. Using these metamodels, the optimal setting for the adjustable stand is determined with robust optimization techniques and the effect on product quality analyzed. It is shown that the subsequent adjustment of the final roll stand position leads to a significantly improved product quality by preventing product defects and minimizing the deteriorating effects of scattering variables

Accuracy and precision assesment of stochastic simulation tools for springback variation

The sheet forming industry is plagued by inherent variations in its many input variables, making quality control and improvements a major hurdle. This is particularly poignant for Advanced High Strength Steels (AHSS), which exhibit a large degree of property variability. Current FE-based simulation packages are successful at predicting the manufacturability of a particular sheet metal components, however, due to their numerical deterministic nature are inherently unable to predict the performance of a real-life production process. Though they are now beginning to incorporate the stochastic nature of production in their codes. This work investigates the accuracy and precision of a current stochastic simulation package, AutoForm Sigma v4.1, by developing an experimental data set where all main sources of variation are captured through precise measurements and standard tensile tests. Using a Dual Phase 600Mpa grade steel a series of semi-cylindrical channels are formed at two Blank Holder Pressure levels where the response metric is the variation in springback determined by the flange angle. The process is replicated in AutoForm Sigma and an assessment of accuracy and precision of the predictions are performed. Results indicate a very good correspondence to the experimental trials, with mean springback response predicted to within 1 &deg; of the flange angle and the interquartile spread of results to within 0.22&deg;.<br /

Simulations of spectral lines from an eccentric precessing accretion disc

Two dimensional SPH simulations of a precessing accretion disc in a q=0.1 binary system (such as XTE J1118+480) reveal complex and continuously varying shape, kinematics, and dissipation. The stream-disc impact region and disc spiral density waves are prominent sources of energy dissipation.The dissipated energy is modulated on the period P_{sh} = ({P_{orb}}^{-1}-{P_{prec}}^{-1}^{-1} with which the orientation of the disc relative to the mass donor repeats. This superhump modulation in dissipation energy has a variation in amplitude of ~10% relative to the total dissipation energy and evolves, repeating exactly only after a full disc precession cycle. A sharp component in the light curve is associated with centrifugally expelled material falling back and impacting the disc. Synthetic trailed spectrograms reveal two distinct "S-wave" features, produced respectively by the stream gas and the disc gas at the stream-disc impact shock. These S-waves are non-sinusoidal, and evolve with disc precession phase. We identify the spiral density wave emission in the trailed spectrogram. Instantaneous Doppler maps show how the stream impact moves in velocity space during an orbit. In our maximum entropy Doppler tomogram the stream impact region emission is distorted, and the spiral density wave emission is uppressed. A significant radial velocity modulation of the whole line profile occurs on the disc precession period. We compare our SPH simulation with a simple 3D model: the former is appropriate for comparison with emission lines while the latter is preferable for skewed absorption lines from precessing discs.Comment: See http://physics.open.ac.uk/FHMR/ for associated movie (avi) files. The full paper is in MNRAS press. Limited disk space limit of 650k, hence low resolution figure file

Contact pressure prediction in sheet metal forming using finite element analysis

Tool wear has become a significant issue associated with the forming of high strength sheet steels in the automotive industry. In order to combat this problem, recent research has been devoted to utilizing the contact results obtained from current sheet metal forming software predictions, in order to develop/apply tool wear models or tool material selection criteria for use in the stamping plant. This investigation aims to determine whether a specialized sheet metal forming software package can correctly capture the complex contact conditions that occur during a typical sheet metal stamping process. The contact pressure at the die radius was compared to results obtained using a general-purpose finite element software package, for a simple channel-forming process. Although some qualitative similarities between the two predictions were observed, it was found that significant differences in the magnitude and distribution of the contact pressure exists. The reasons for the discrepancies in results are discussed with respect to the simplifications and assumptions adopted in the finite element model definitions, and with regards to other results available in the literature.<br /

Development of material models to predict the crashworthiness of tubes

Metallic tubes have been extensively studied for their crashworthiness as they closely resemble automotive crash rails. Recently, the demand to produce light weight yet safer vehicles has led to the need to understand the behaviour of novel materials such as composites, metallic foams and sandwich structures durign a crash. This paper presents a method to predict the crashworthiness of structural components using material modes. The material factors that most affect the crushing response are determined and quantified by developing and validating the crushing of a square tube model in Abaqus. The inputs from the model are used to construct a simple, physically realistic constitutive model and new test methods for predicting the material behaviour at high strain rates using low test speeds. These material models enable a designer to predict the crash behaviour of a structure without the need to perform extensive physical tests, thus reducing the time and cost of development

Elucidating the role of hyperfine interactions on organic magnetoresistance using deuterated aluminium tris(8-hydroxyquinoline)

Measurements of the effect of a magnetic field on the light output and current through an organic light emitting diode made with deuterated aluminium tris(8-hydroxyquinoline) have shown that hyperfine coupling with protons is not the cause of the intrinsic organic magnetoresistance. We suggest that interactions with unpaired electrons in the device may be responsible.Comment: Submitte

Establishment of leucaena in Australia

Leucaena (Leucaena leucocephala ssp. glabrata) is a highly productive tropical perennial legume used primarily in extensive beef grazing systems across northern Australia. Its productivity provides substantial benefits to grazing businesses and economically significant areas of leucaena have been established in Queensland, with much smaller areas in both the Northern Territory and Western Australia. Specific environmental conditions (particularly soil type) and management practices are required to obtain reliable establishment and high productivity from leucaena-grass grazing systems. Significant research, development and extension have been undertaken in northern Australia, particularly in central Queensland, resulting in management packages which ensure establishment reliability and long-term productivity. However expansion into new areas can be constrained by regionally-specific establishment issues. Adaptation of known establishment and management practices together with research and development are required for leucaena-grass grazing systems in new regions

Model-T2 - Development of a low-cost sustainable vehicle: Collaboration models in concept car design

One of the largest problems facing the world today is the rise of Indian and Chinese car owners, and their lack of access to low cost sustainable vehicles. China and India have very low vehicle ownership per capita, however, this is quickly changing. Both their Governments are heavily investing in sustainable vehicle technologies to reduce green house gas emissions, and reduce each countries dependency on oil. This paper will outline a new sustainable vehicle that can compete with the low cost vehicles currently avaliable. This novel concept was the inspiration from a cross-functional team comprising engineers and designers working on a low-cost sustainable concept car project, the Model T2. The main features of this concept are: world first $7000 sustainable vehicle, an incredible light weight structure, and a novel steering mechanism for maximum maneuverability

Mind the Gap

Mind the Gap sought to improve the metacognition and academic attainment of pupils in Year 4. There were two aspects to the intervention. The first involved training teachers in how to embed metacognitive approaches in their work, and how to continue to effectively and strategically involve parents. This training took place over a day and was provided by a consultant. The second component focused on parental engagement and offered families the opportunity to participate in a series of facilitated workshops where children and parents work together to create an animated film. Sessions were coordinated by a practitioner who helped participants to think about how they are learning, create learning goals and reflect on their progress; to be metacognitive about the learning process they were engaged in together. The families were offered 2 hours of workshops per week for 5 weeks (10 hours in total). The project targeted schools in four areas of England: Birmingham, Devon, London and Manchester. It was delivered by the Campaign for Learning, with assessments carried out by Durham University. Delivery started in September 2012 and finished in October 2013. The project was evaluated using a randomised controlled trial, which compared the interventions to a ‘business-as-usual’ control group. It is important to note that it was eligibility for the animation course, not participation, that was randomised, so the results must be regarded as estimating the effect of being offered the animation course (alone or in combination with teacher training, as appropriate) rather than participating in it

Fatigue Behavior of Welded Connections Enhanced with UIT and Bolting

A common problem in bridges employing welded steel girders is development of fatigue cracks at the ends of girder coverplates. Fatigue cracks tend to form at the toes of the transverse welds connecting a coverplate to a girder flange since this detail has a region of very high stress concentration. Because many aging bridges employ these fatigue-prone, AASHTO fatigue Category E or E' details, a means to effectively enhance the fatigue lives of these details is being sought. A research project funded by the Kansas Department of Transportation was undertaken at the University of Kansas to investigate the fatigue life enhancement afforded by two retrofit methods. One retrofit method was similar to a method described in the AASTHO Bridge Design Specification (AASHTO 2004) and involved pretensioned bolts being added to the ends of coverplates near the transverse welds. Unlike the AASHTO bolting procedure, the modified bolting procedure studied during this project utilized coverplates having transverse fillet welds that were left in the as-fabricated state. The other retrofit method was the use of a proprietary needle peening procedure called Ultrasonic Impact Treatment (UIT). Results of the research project showed that UIT was highly effective at enhancing the fatigue lives of coverplate end details while the bolting procedure was ineffective. Weld treatment with UIT resulted in an improvement in fatigue life over control specimens by a factor of 25. This translated in an improvement from an AASTHO fatigue Category E detail rating to and AASHTO fatigue Category A detail rating. The modified coverplate bolting procedure tested during this project had either no effect on fatigue life or, in some cases, had a detrimental effect on fatigue life. The coverplate bolting procedure included in the AASHTO specification allows a coverplate end detail to achieve a fatigue Category B resistance when bolted rather than transversely welded. 11 Therefore, the modified bolting procedure tested during this project was much less effective at enhancing fatigue life than either the AASHTO bolting procedure or UIT