Reduction of springback by intelligent sampling-based LSSVR metamodel-based optimization

This paper deals with the variable blank holder force in sheet metal forming in order to reduce springback effects after forming. A structural risk minimization principle-based metamodeling technique, least square support vector regression (LSSVR) method is applied to optimization. In order to improve the efficiency, an intelligent sampling strategy proposed by Wang et al. (Mater Des 30:1468–1479, 2009a) is integrated with the LSSVR. Therefore, the proposed strategies establish an adaptive metamodeling optimization system. The optimization procedure can be carried out automatically. To valid the flexibility of this system, the presented method is used to optimize the variable blank force parameters of the models from NUMISHEET’96 and torsion rail model. Compared with other popular metamodel-based optimization methods, the test results demonstrate the potential capability for nonlinear engineering problems.     

Reduction of radioactive waste volume using selective crystallization processes

Satisfactory combination of small volume of compositions incorporating ¹³⁷Cs, ⁹⁰Sr, and ²⁴⁴Cm with the admissible heat release rate can be attained by crystallization of definite compounds from high-level solutions. The concentrate of cesium isotopes is obtained by their precipitation in the form of phosphoromolybdate and, after additional storage, in the form of CsMgPO₄·6H₂O; the concentrate of Am, Cm, Sr, Ba, and Ln can be obtained using the known but somewhat modified (increased pH of solution) OXAL process. It is appropriate to remove Am and long-lived Cm isotopes from this concentrate also after storage ensuring the decay of ⁹⁰Sr and ²⁴⁴Cm. The remaining rare-earth elements with traces of Am and Cm and stable isotopes of Sr and Ba can be disposed of, e.g., in the form of a mineral-like phosphate.     

型材拉弯的力学与回弹分析

回弹是弯曲成形中普遍存在的现象,是由卸载过程中内力重新分布引起的,回弹的存在直接影响弯曲件的成形精度.本文针对转台拉弯成形过程,对等边型材等曲率拉弯进行了应力-应变分析,并按照卸载预拉力与不卸载预拉力两种情况对工件回弹进行了研究与探讨,得到两组半径回弹率理论曲线.通过与试验结果对比,不卸载拉力计算的结果与试验值比较吻合.     

铝合金矩形管拉弯成形过程的数值模拟

采用动力显式有限元程序Pam-Stamp2000对铝合金矩形管的一种拉弯成形过程进行了模拟,分析了模具最大作用力、管材截面畸变、成形件回弹的变化规律.模拟结果和文献给出的实验结果相当吻合,即模具最大作用力、管材截面畸变均随预拉力的增加而增加,而成形零件的回弹随预拉的增加而减小;相同预拉状况下,增加壁厚有利于减小截面畸变.此外,数值模拟给出了模具对管材作用力及管材夹持端轴向拉伸作用力随模具行程的变化规律,揭示了本文的拉弯实质上是一种非恒定轴向作用力(呈渐增趋势)的拉弯成形方式,这与本文的解析结果高度一致.     

A two-pronged approach for springback variability assessment using sparse polynomial chaos expansion and multi-level simulations

In this study, we show that stochastic analysis of metal forming process requires both a high precision and low cost numerical models in order to take into account very small perturbations on inputs (physical as well as process parameters) and to allow for numerous repeated analysis in a reasonable time. To this end, an original semi-analytical model dedicated to plain strain deep drawing based on a Bending-Under-Tension numerical model (B-U-T model) is used to accurately predict the influence of small random perturbations around a nominal solution estimated with a full scale Finite Element Model (FEM). We introduce a custom sparse variant of the Polynomial Chaos Expansion (PCE) to model the propagation of uncertainties through this model at low computational cost. Next, we apply this methodology to the deep drawing process of U-shaped metal sheet considering up to 8 random variables.     

Numerical assessment of springback for the deep drawing process by level set interpolation using shape manifolds

In this paper, we introduce an original shape representation approach for post-springback characterization based on the automatic generation of parameterized level set functions. The central idea is the concept of the shape manifold representing the design domain in the reduced-order shape-space. Performing Proper Orthogonal Decomposition on the shapes followed by using the Diffuse Approximation allows us to efficiently reduce the problem dimensionality and to interpolate uniquely between admissible input shapes, while also determining the smallest number of parameters needed to characterize the final formed shape. We apply this methodology to the problem of springback assessment for the deep drawing operation of metal sheets.     

Oxidation processes using ion beams

Recent work demonstrates that reactive ion beams can be used to grow compound layers on metal and semiconductor surfaces. Ion beams are characterized by easily controlled ion flux and energy, with a narrow energy spread. Also, the ion species are delivered to the sample in a low pressure environment. These advantages allow greater control and simpler analysis of compound formation processes than other techniques do. Ion beam oxidation is reviewed and compared with thermal, plasma and r.f. oxidation and with oxidation by ion implantation. The ion energy range of several electronvolts to hundreds of electronvolts is suitable for depositing the oxidizing species in the metal in an active state, and simultaneous sputtering can produce a self-limiting oxide thickness when the sputtering yield and oxidation rate are in proper balance. The process of ion beam oxidation is also discussed in light of the etching behavior of metals under combined inert gas and oxygen ion bombardment and of the related technique of reactive ion beam sputter deposition using ion bombardment of a growing film. Additional examples are drawn from the use of other reactive ion beam species, including nitrogen and hydrogen.     

Study on springback from thermal-mechanical boundary condition imposed to V-bending and L-bending processes coupled with infrared rays local heating

This paper shows differences of thermal-mechanical boundary condition and springback between V-bending and L-bending processes. Although a recently conducted study showed that an infrared (IR) local heating method substantially reduces springback of dual-phase (DP) 980 steel sheet in V-bending, its application to L-bending, which is one of widely used forming processes in industrial applications, has not been sufficiently reported. In the L-bending experiment conducted in this work, springback does not sufficiently decrease as much as it does in the V-bending test, even though the sheet is deformed under the same temperature condition. For analysis of the difference in springback, thermo-elastic-plastic simulation for both V-bending and L-bending processes were conducted. The numerical analysis shows that the V-bending and L-banding processes have significantly different thermal and mechanical boundary conditions even though both processes go through a bending deformation. The differences in the boundary conditions have a strong effect on the thermal-mechanical behavior of the blank, so that the springback results are different between the two bending processes. Finally, it is also shown that the L-bending process requires a higher temperature condition than the V-bending process in order to sufficiently reduce springback.     

Reduction of clinkerization temperature by using phosphogypsum

Valorization of phosphogypsum as mineralizer in the burning of Portland cement clinker was studied in our laboratory. X-ray fluorescence, optical microscope technique and powder X-ray diffraction were then used to characterize the synthesized clinker and its raw mixture in terms of chemical composition and clinker mineralogical composition. The effects of phosphogypsum on structural and morphological properties of clinker minerals and on the presence of alite were followed by scanning electron microscopy combined with microprobe analysis. The addition of phosphogypsum to the cement raw mixture shows that the burning temperature decreases and therefore improves the production process of clinker. The addition of 10% phosphogypsum permits a complete clinkerization at low burning temperature (1200 degrees C), instead of 1470 degrees C, which increases the cement factory efficiency by 25% and extends the service life of furnace fire brick. Structural and morphological analysis of clinker produced under the new conditions show that phosphogypsum preserve perfectly the crystalline structure of silicate phases, which leads to the improvement of physical and mechanical properties of cement.     

Investigation of SHS processes using laser hardening

Using the titanium-boron system as an example, a procedure for ultrafast hardening (10⁶–10⁷ K/sec) of the SHS reaction using pulse laser radiation is developed. The dynamic scheme of the component interaction is obtained on the basis of metallographical and micro X-ray spectrum analysis. It is shown that under conditions of high-speed heating mass transfer on the interfaces has a pronounced convective character, ensuring an increased interaction rate.Institute of Structural Macrokinetics of the Russian Academy of Sciences, Tomsk Branch. Scientific-Research Institute of Applied Mathematics and Mechanics. Translated from Inzhenerno-Fizicheskii Zhurnal, Vol. 65, No. 5, pp. 598–601, November, 1993.     

Ultrasonic ranging sensor using simultaneous emissions from different transducers

In recent applications based on ultrasound, several ultrasonic transducers have been geometrically and electronically associated to constitute a global sensor. There are several different methods used to process the ultrasonic signals obtained from these transducers. In this work, multimode techniques using Golay complementary sequences are proposed for processing the ultrasonic signal. The system increases scan rate, precision, and reliability. It is also capable of echo discrimination, allowing simultaneous measurements to be made and detection of the same obstacle by different transducers without cross-talk problems. The real-time implementation of the algorithm is presented on a field-programmable gate array (FPGA) device.     

Fault diagnosis of batch processes using discriminant model

A new statistical online diagnosis method for a batch process is proposed. The proposed method consists of two phases: offline model building and online diagnosis. The offline model building phase constructs an empirical model, called a discriminant model, using various past batch runs. When a fault of a new batch is detected, the online diagnosis phase is initiated. The behaviour of the new batch is referenced against the model, developed in the offline model building phase, to make a diagnostic decision. The diagnosis performance of the proposed method is tested using a dataset from a PVC batch process. It has been shown that the proposed method outperforms existing PCA-based diagnosis methods, especially at the onset of a fault.     

The grain shape dependence of springback of integrated circuit leadframes

Anisotropy is known to be an important factor in affecting springback and deformation behaviour of cold rolled integrated circuit (IC) leadframes. Less work has been carried out to study the effect of grain shape on springback of IC leadframes, though it is considered to be a source of plastic anisotropy. In this paper, a plane stress model based on the concept of relaxed constraints has been developed to investigate the effect of grain shape on springback of a cold rolled copper alloy. Comparisons between the predictions by the relaxed constraint model and the conventional full constraints model and the experimental results have been made. It is found that significant improvement has been obtained by using the new model.     

Reduction of titanium and other metal oxides using electrodeoxidation

Abstract

Many reactive and refractory metals are currently produced industrially by reducing their compounds, including oxides, using a more reactive metal. In some cases, where there is substantial oxygen solubility in the metal, the oxygen is first removed by carbochlorination followed by reduction. Titanium and zirconium are made by reduction of the volatile tetrachlorides by magnesium. The processes consist essentially of two reduction steps: reducing magnesium chloride to magnesium metal and then reduction of the metal compound; this makes the overall reduction process relatively expensive. Electrodeoxidation is very simple in that the oxide to be reduced is rendered cathodic in molten alkaline earth chloride. By applying a voltage below the decomposition potential of the salt, it has been found that ionisation of oxygen is the dominant cathode reaction, rather than alkaline earth metal deposition. In the laboratory, this technique has been applied to reduce a large number of metal oxides to the metals, including titanium, zirconium, chromium, niobium, tantalum, uranium and nickel. Furthermore, when mixed oxides are used as the cathode, alloys or intermetallic compounds of uniform composition are obtained. This may offer advantages over conventional technology for those alloys that are difficult to prepare at present, owing to differences in either density or vapour pressure.     

板料V形弯曲回弹的动力显式有限元分析

板料成形后的回弹对精度影响较大,在数值模拟时对回弹进行精确预测显得非常重要.基于连续介质力学及有限变形理论,建立了适合于三维板料成形分析的显式算法的有限元数学模型,采取集中质量矩阵,用动力显式积分的方法,使位移计算显式化,避免了由材料、几何、边界条件等高度非线性因素引起的计算收敛问题.根据该模型开发了动力显式算法的板料成形过程模拟的有限元分析程序DESSFORM3D,应用该软件模拟了包括回弹在内的整个板料V形弯曲的成形过程.通过3个不同凸模行程时计算与实验的板料几何形状对比以及计算结果与实验结果对比,验证了软件计算结果的准确性.     

管材数控弯曲回弹规律的有限元分析

回弹是管材弯曲卸载后必然发生的现象,并严重影响弯曲管件的精度和管材弯曲生产的效率.成形参数对管材弯曲卸载后的回弹有重要的影响.为了研究成形参数对回弹角的影响,基于弹塑性有限元软件ANSYS建立了管材数控弯曲及回弹的有限元模型,以不锈钢管弯曲及回弹过程为典型研究对象,实验验证了所建立的有限元模型的可靠性,并分析了部分工艺和材料性能参数对管材数控弯曲回弹的影响规律.结果表明:回弹角随弯曲角、芯棒与管壁间隙及材料硬化系数的增大而增大,随材料硬化指数的增大而减小.     

Diffractive simultaneous bidirectional shearing interferometry using tailored spatially coherent light

Measurements of wavefront deformations can be carried out with the help of lateral shearing interferometers. Here the focus is on a setup providing two shears along orthogonal directions simultaneously to generate the data needed for a reconstruction. We describe a diffractive solution using Ronchi phase gratings with a suppressed zeroth order for both the doubling of the wavefront under test and the bidirectional shearing unit. A series arrangement of the gratings offers an on-axis geometry, which minimizes the systematic errors of the test. For illumination, an extended incoherent monochromatic light source is used. High-contrast fringes can be obtained by tailoring the degree of coherence via a periodic intensity distribution.     

压力容器O形金属密封环的回弹行为研究

通过弹塑性有限元接触分析和循环压扁试验,对60Si2Mn、304不锈钢和TA16材料O形密封环管材在室温条件下的回弹行为进行了研究。结果表明:TA16合金O形管状试样回弹量H与60Si2Mn钢回弹量较为接近,且为304不锈钢回弹量的2～3倍;提出了用于O形环回弹量预测的回弹模型,该模型对这3种金属材料O形管状试样的预测结果和实验结果具有很好的一致性。