The ring compression test: Analysis of dimensions and canonical geometry

The compression ring test is universally accepted as a perfectly valid method by which determine simply and reliably the adhesion friction factor in a plastic deformation process. Its methodology is based on the application of geometric changes as both the reduction in thickness as the decrease in bore inner diameter in the strained ring itself. In this paper the performance of that test is the basis for establishing the coefficient of friction on a forging process so that, given this, its application to Upper Bound Theorem (UBT) by model Triangular Rigid Zones (TRZ), enable the establishment an intercomparison with empirical force, reaching a cuasivalidation of this Theorem in a certain range.Universidad de Málaga. Campus de Excelencia Internacional Andalucía Tec

A comparative study of image processing thresholding algorithms on residual oxide scale detection in stainless steel production lines

The present work is intended for residual oxide scale detection and classification through the application of image processing techniques. This is a defect that can remain in the surface of stainless steel coils after an incomplete pickling process in a production line. From a previous detailed study over reflectance of residual oxide defect, we present a comparative study of algorithms for image segmentation based on thresholding methods. In particular, two computational models based on multi-linear regression and neural networks will be proposed. A system based on conventional area camera with a special lighting was installed and fully integrated in an annealing and pickling line for model testing purposes. Finally, model approaches will be compared and evaluated their performance..Universidad de Málaga. Campus de Excelencia Internacional Andalucía Tech

Application of the Upper Bound Theorem to indentation processes with tilted punch by means of Modular Model

Nowadays, the indentation processes are resuming it importance due to the new deformation processes that are being developed, as the Incremental Forming Process (IFP) or the Localized-Incremental Forming Process (LIFP) [1]. In this paper, a tilt punch is considered in order to cover the largest possible number of cases in the study of the indentation,. Thus, using combinations of flat and tilt punches, it will be possible to analyze complex geometries in future studies. Present study shows the analysis of the indentation process by the Upper Bound Theorem (UBT), when it is performed with a tilt punch. A modular model is developed, compound by two modules of Triangular Rigid Zones (TRZ) each [2], which adapts to the configuration of the punch.Universidad de Málaga. Campus de Excelencia Internacional Andalucía Tech

Upper bound solutions of ring compression test

El presente trabajo aborda una particularización del proceso de forja, estudiando la deformación de un anillo. El conformado plástico se realiza mediante el empleo del Teorema del Límite Superior y siguiendo el modelo de Bloques Rígidos Triangulares para calcular la carga mínima necesaria para deformar plásticamente la pieza. Se establece la pieza a deformar como un anillo de geometría determinada por el denominado Ensayo de Compresión de Anillo (Ring Compression Test) bajo su configuración canónica, justificándose asimilar el proceso a uno de deformación plana. Se plantea desde una nueva perspectiva el estudio del radio neutro (radio a partir del cual el material de la pieza fluye en sentidos contrarios), elemento clave en la solución del problema.Universidad de Málaga, C.E.I. Andalucía Tec

Analysis of the Effect of the Surface Inclination Angle on the Roughness of Polymeric Parts Obtained with Fused Filament Fabrication Technology

The aim of this work was to conduct a dimensional study, in terms of microgeometry, using parts from an additive manufacturing process with fused filament fabrication (FFF) technology. As in most cases of additive manufacturing processes, curved surfaces were obtained via approximation of planes with different inclinations. The focus of this experimental study was to analyze the surface roughness of curve geometry from surface-roughness measurements of the plane surfaces that generate it. Three relevant manufacturing parameters were considered: layer height, nozzle diameter and material. Taguchi’s experimental design based on the Latin square was applied to optimize the set of specimens used. For the manufactured samples, the surface-roughness parameters Ra (roughness average), Rq (root mean square roughness) and Rz (maximum height) were obtained in eight planes of different inclinations (0° to 90°). The results were analyzed using both a graphical model and an analysis of variance study (ANOVA), demonstrating the dependency relationships among the parameters considered and surface finish. The best surface roughness was reached at 85°, with a global average Ra value of 8.66 µm, increasing the average Ra value from 6.39 µm to 11.57 µm according to the layer height increase or decreasing it slightly, from 8.91 µm to 8.41 µm, in relation to the nozzle diameter increase. On the contrary, the worst surface roughness occurred at 20°, with a global average Ra value of 19.05 µm. Additionally, the theoretical profiles and those from the surface-roughness measurement were found to coincide greatly. Eventually, the eight regression curves from the ANOVA allowed prediction of outputs from future specimens tested under different conditions.Partial funding for open access charge: Universidad de Málag

Analysis of the Effect of the Surface Inclination Angle on the Roughness of Polymeric Parts Obtained with Fused Filament Fabrication Technology

The aim of this work was to conduct a dimensional study, in terms of microgeometry, using parts from an additive manufacturing process with fused filament fabrication (FFF) technology. As in most cases of additive manufacturing processes, curved surfaces were obtained via approximation of planes with different inclinations. The focus of this experimental study was to analyze the surface roughness of curve geometry from surface-roughness measurements of the plane surfaces that generate it. Three relevant manufacturing parameters were considered: layer height, nozzle diameter and material. Taguchi’s experimental design based on the Latin square was applied to optimize the set of specimens used. For the manufactured samples, the surface-roughness parameters Ra (roughness average), Rq (root mean square roughness) and Rz (maximum height) were obtained in eight planes of different inclinations (0◦ to 90◦). The results were analyzed using both a graphical model and an analysis of variance study (ANOVA), demonstrating the dependency relationships among the parameters considered and surface finish. The best surface roughness was reached at 85◦, with a global average Ra value of 8.66 µm, increasing the average Ra value from 6.39 µm to 11.57 µm according to the layer height increase or decreasing it slightly, from 8.91 µm to 8.41 µm, in relation to the nozzle diameter increase. On the contrary, the worst surface roughness occurred at 20◦, with a global average Ra value of 19.05 µm. Additionally, the theoretical profiles and those from the surface-roughness measurement were found to coincide greatly. Eventually, the eight regression curves from the ANOVA allowed prediction of outputs from future specimens tested under different conditions

The Upper Bound Theorem in forging processes: Model of Triangular Rigid Zones on parts with horizontal symmetry

The analysis to determine the necessary forces with which to achieve a plastic deformation in metallic materials, in particular, in forging processes and under conditions of plain strain, has been raised over the years through a double approach; on the one hand, by analytical methods that involve a great complexity in their developments but that allow a direct understanding of the parameters that direct these processes. On the other hand, numerical methods, in which, thanks to the enormous development of computer technology, they provide solutions with a high approximation but, in most cases, do not allow to interpret independently the effect of each one of the parameters that come into play. The development of computers relegated analytical methods to the background. An alternative of great interest to apply these methods comes from the study of the Upper Bound Theorem by means of the Triangular Rigid Zones (TRZ) Model. One of the main limitations in the application of this model come from the fact that it is necessary to define a kinematically admissible velocity field and for complex geometric configurations of parts, this field becomes increasingly complicated. A new approach has delimited, from a theoretical perspective, a modular configuration based on a General Module formed by three TRZ that adapts to any geometry of flat surfaces of the part. Another limitation of the Upper Bound Method is the consideration of the plain strain represented by a flat section with double symmetry. Obviously, this imposition only allows to study a limited number of part configurations, which restricts its application in forging processes since the great majority of forged parts do not present geometrically this double symmetry. The present work releases one of these boundary conditions allowing to expand the possibilities of application of this method.Universidad de Málaga. Campus de Excelencia Internacional Andalucía Tec

Creation of a virtual museum as a learning tool in the teaching of the Manufacturing Engineering subject

Teaching subjects such as Manufacturing Engineering requires the use of effective teaching tools, which help students in their learning process. While the traditional transmission model can be effective when teaching concepts and theoretical contents, others activities are essential to allow students to participate, act or reflect, thus developing skills and competences, such us communication, teamwork, and creativity. This paper presents a learning tool based on the creation of a virtual museum related to the Manufacturing Engineering field, which is included as a coursework in the teaching program of the subject "Manufacturing Engineering". This subject is taught at the second year of different degrees at the Industrial Engineering School of the University of Malaga and a percentage of its final grade comes from this activity. The museum is materialized through the posters whose format is similar to those presented at conferences and whose content may be referred to three topics (object, process or biography). Once the students are given the necessary instructions, each project is selected by a work group and its development is supervised in the next two sessions by the lecturer. In the final stage, each group give the presentation about their work. The analysis of the students’ grades obtained from both this activity and the whole subject makes it possible to quantify the impact of this type of activities on the student learning and achievement. Eventually, best posters will be part of the department collection, being accessible to students in subsequent years.Universidad de Málaga. Campus de Excelencia Internacional Andalucía Tech

Detection of emerging faults in power transformers using self-organising maps

Power transformers are a crucial part of the power system, one of the largest infrastructures in industrialised countries. In particular, wind turbine transformers are subjected to frequent thermal cycling as a function of varying turbine loads. Thus transformers are prone to developing faults and defects that can involve high repair costs for instance due to the repeated thermal stress on the winding. Faults develop mainly when the insulation produces small leakage currents between turns, which if not detected early, might become short circuits that can result in interruptions in electricity supply, and difficult and costly repairs. An optimum overhaul of damaged transformers is not accomplished often because of lack of appropriate inspection tools. Detailed assessment and preventive maintenance work, which will allow the detection and repair of failures at early stages, is believed to be the only suitable way to cope with power transformer degradation at low cost. This paper presents a methodology based on the analysis of current signals converted by the S transform for the detection of incipient faults in transformers. The procedure is based on calculating the energy of the zones of the time-frequency spectrum. Its main advantage is its possible real time implementation that can be applied while the transformer is in use. Experimental results with PSCAD are presented.Universidad de Málaga. Campus de Excelencia Internacional Andalucía Tec

The Upper Bound Theorem in Forging Processes: Model of Triangular Rigid Zones on Parts with Horizontal Symmetry

This paper presents the analytical method capacity of the upper bound theorem, under modular approach, to extend its application possibilities. Traditionally, this method has been applied in forging processes, considering plane strain condition and parts with double symmetry configuration. However, in this study, the double symmetry is eliminated by means of a fluency plane whose position comes from the center of mass calculated. The study of the load required to ensure the plastic deformation will be focus on the profile of the part, independently on both sides of the fluence plane, modifying the number and the shape of the modules that form the two halves in which the part is defined. This way, it is possible to calculate the necessary load to cause the plastic deformation, whatever its geometric profile