A study on optimal design of process parameters in single point incremental forming of sheet metal by combining Box–Behnken design of experiments,response surface methods and genetic algorithms

Incremental forming is a sheet metal forming process characterized by high flexibility; for this reason, it is suggested for rapid prototyping and customized products. On the other hand, this process is slower than traditional ones and requires in-depth studies to know the influence and the optimization of certain process parameters. In this paper, a complete optimization procedure starting from modeling and leading to the search of robust optimal process parameters is proposed. A numerical model of single point incremental forming of aluminum truncated cone geometries is developed by means of Finite Element simulation code ABAQUS and validated experimentally. One of the problems to be solved in the metal forming processes of thin sheets is the taking into account of the effects of technological process parameters so that the part takes the desired mechanical and geometrical characteristics. The control parameters for the study included wall inclination angle (α), tool size (D), material thickness (Th_ini), and vertical step size (In). A total of 27 numerical tests were conducted based on a 4-factor, 3-level Box–Behnken Design of Experiments approach along with FEA. An analysis of variance (ANOVA) test was carried out to obtain the relative importance of each single factor in terms of their main effects on the response variable. The main and interaction effects of the process parameters on sheet thinning rate and the punch forces were studied in more detail and presented in graphical form that helps in selecting quickly the process parameters to achieve the desired results. The main objective of this work is to examine and minimize the sheet thinning rate and the punch loads generated in this forming process. A first optimization procedure is based on the use of graphical response surfaces methodology (RSM). Quadratic mathematical models of the process were formulated correlating for the important controllable process parameters with the considered responses. The adequacies of the models were checked using analysis of variance technique. These analytical formulations allow the identification of the influential parameters of an optimization problem and the reduction of the number of evaluations of the objective functions. Taking the models as objective functions further optimization has been carried out using a genetic algorithm (GA) developed in order to compute the optimum solutions defined by the minimum values of sheet thinning and the punch loads and their corresponding combinations of optimum process parameters. For validation of its accuracy and generalization, the genetic algorithm was tested by using two analytical test functions as benchmarks of which global and local minima are known. It was demonstrated that the developed method can solve high nonlinear problems successfully. Finally, it is observed that the numerical results showed the suitability of the proposed approaches, and some comparative studies of the optimum solutions obtained by these algorithms developed in this work are shown here.     

Identification of the beat characteristics and damping ratios of the Hwacheon World Peace Bell using wavelet transform

In this paper, a new measurement technique is proposed to identify the beat characteristics and modal damping ratios of a Korean bell in the casting field. The beat response caused by the mutual interference of mode pair with very close doublet frequency is unique feature of the Korean bell and should be accurately measured in order to quantitatively estimate the bell sound. However, the conventional method based on a filtering concept such as the Fourier transform has difficulty in extracting the beat frequencies and modal damping ratios because the method should individually decompose the measured signal into each mode. The aim of this paper is to propose an effective measurement method to identify the beat frequencies, mode pairs and modal damping ratios using the continuous wavelet transform in a real striking condition. The proposed method is verified with the Hwacheon World Peace Bell cast in the year 2008, which is the largest bell in Korea. In the future, the proposed method can be applicable to the casting field of the Korean bell to effectively estimate its beat characteristics and damping characteristics.     

Extraction of the damping ratio of a beat wave using envelope logarithmic decrement

A phenomenon called “beat” occurs in bell structures with slight asymmetry, wherein the vibration and the sound periodically fluctuate with respect to strength. In oriental bells, beat makes the bell sound grand and lively. The audience wants to hear the bell sound with a strong beat for as long as possible. The modal damping ratio is used as a physical factor to evaluate the duration of the beat sound. For low damping, the modal damping ratio can be extracted using the logarithmic decrement method with a single-frequency time signal. However, because the beat wave includes two adjacent frequencies, the conventional logarithmic decrement method cannot be applied. In this study, a method for extracting the damping ratio from the envelope data of beat waves was proposed and verified experimentally. Finally, the method was applied to evaluate the duration of the beat sound of the 2018 Winter Olympic bell.

     

Unified synthesis of Watt-I six-link mechanisms using evolutionary optimization

A Watt-I mechanism can operate in eight different combinations of assembly modes and output link. In this paper, a novel approach is presented for carrying out unified optimum synthesis of various combination types of Watt-I mechanism, irrespective of whether identical or different ranges of variables are specified for different combination types. By carrying out unified synthesis the less suited combination types can be identified, leading to their elimination from the synthesis process. This results in a saving of the overall computational time. The presented approach can be implemented with most of the evolutionary optimization methods. In this paper, the Differential Evolution algorithm is chosen as the optimization method. Unified optimization results are presented for two problems. The proposed approach is general and can be used, with suitable modifications, to carry out unified optimum design of alternate mechanical systems which can perform a given task.     

Unsteady flow simulations in a three-lobe positive displacement blower

To improve the performance of the positive displacement blower, it is imperative to understand the detailed internal flow characteristics or enable a visualization of flow status. However, the existing two-dimensional unsteady, three-dimensional steady or quasi-unsteady numerical simulation and theoretical analysis cannot provide the detailed flow information, which is unfavorable to improve the performance of positive displacement blower. Therefore, the unsteady flow characteristics in a three-lobe positive displacement blower are numerically investigated by solving the three-dimensional, unsteady, compressible Navier-Stokes equations coupled with RNG k-e turbulent model. In the numerical simulation, the dynamic mesh technique and overset mesh updating method are adopted. Due to the air being compressed in the process of the rotors rotating, the variation of the temperature field in the positive displacement blower is considered. By comparing the experimental measurements and the numerical results on the variation of flow rate with the outlet pressure, the maximum relative error of the flow rate is less than 2.15% even at the maximum outlet pressure condition, which means that the calculation model and numerical computational method used are effective. The numerical results show that in the intake region, the fluctuations of the inlet flow are greatly affected by the direction of the velocity vectors. In the exhaust region, the temperature changes significantly, which leads to the increase of the airflow pulsation. Through analysis on the velocity, pressure and temperature fields obtained from the numerical simulations, three-dimensional unsteady flow characteristics in the positive displacement blower are revealed. The studied results will provide useful reference for improving the performance and empirical correction in the design of the positive displacement blower.     

Theoretical Investigation of the Viscous Damping Coefficient of Hydraulic Actuators

The viscous damping coefficient(VDC) of hydraulic actuators is crucial for system modeling,control and dynamic characteristic analysis.Currently,the researches on hydraulic actuators focus on behavior assessment,promotion of control performance and efficiency.However,the estimation of the VDC is difficult due to a lack of study.Firstly,using two types of hydraulic cylinders,behaviors of the VDC are experimentally examined with velocities and pressure variations.For the tested plunger type hydraulic cylinder,the exponential model B=αυ~(-β),(α0,β0)or B=α_1e~(-β_1υ)+α_2e~(-β_2υ)(α_1,α_20,β_1,β_20),fits the relation between the VDC and velocities for a given pressure of chamber with high precision.The magnitude of the VDC decreases almost linearly under certain velocities when increasing the chamber pressure from 0.6 MPa to 6.0 MPa.Furthermore,the effects of the chamber pressures on the VDC of piston and plunge type hydraulic cylinders are different due to different sealing types.In order to investigate the VDC of a plunger type hydraulic actuator drastically,a steady-state numerical model has been developed to describe the mechanism incorporating tandem seal lubrication,back-up ring related friction behaviors and shear stress of fluid.It is shown that the simulated results of VDC agree with the measured results with a good accuracy.The proposed method provides an instruction to predict the VDC in system modeling and analysis.     

Studies of the Kinetics of Lithium Grease Microstructure Regeneration by Means of Dynamic Oscillatory Rheological Tests and FTIR–ATR Spectroscopy

As part of this research, the kinetics of soap grease thickener microstructure regeneration during 24-h relaxation after 1-h shearing were studied. A lubricating grease, based on mineral oil ORLEN OIL SN-400, containing associated molecules of lithium 12-hydroxystearate was subjected to analysis. Rheological dynamic oscillatory and FTIR–ATR (Fourier Transform Infrared Attenuated Total Reflectance) spectroscopy were used to study the kinetics of thickener microstructure regeneration. Changes in the values of storage modulus G′ and loss modulus G″ of the investigated grease during its relaxation in the linear viscoelastic range were examined. In addition, the mechanical stability of the thickener microstructure at a variable oscillation frequency was tested, and changes in the cohesive energy of the grease versus the latter’s relaxation time were assessed. FTIR–ATR spectroscopy was used to study the physicochemical interactions between the associated molecules of lithium 12-hydroxystearate. Infrared bands were assigned to the vibrations of the particular functional groups of the grease components, and the spectral parameters in the absorption spectra in the range of 700–3,700 cm^?1 were examined. The studies carried out using the two investigative methods have revealed that the intensity of thickener microstructure regeneration was the highest in the first hour of grease relaxation after shearing. In this time interval, the largest changes in the vibrations of the main functional groups of the grease components were observed. In the next hours, the kinetics of thickener microstructure regeneration were substantially lower.     

A study of the method for measuring the local size distribution of spherical particles diffusing in a fluid by L.D.A.

This work concerns a method for measuring the local size distribution of spherical particles diffusing in a fluid. It is based on the light scattering theory and makes use of an ordinary Laser Doppler Anemometry apparatus. The required information is obtained by analyzing and processing the signal from the PM, which observes the measuring volume at the angle of 90. The pinhole is replaced by a slit oriented in such a way that the intensity of the scattered light depends only on the diameter of the particle and on a single space variable. A direct calibration of the response of the optical system is used to compute the size distribution from the scattered light probability density.     

Experimental and numerical investigation of the wake structure and aerodynamic loss of trailing edge jet

The influence of the velocity ratio (VR) between the jet and main flow on the wake structure and aerodynamic loss of the trailing edge jet is studied using particle image velocimetry and numerical simulations. Three different velocity ratios, namely, VR = 0.5, 1.0, 1.5, are chosen for this comparative study. The Reynolds number (Re _h ) based on the slot height (h) and the mainstream velocity (U₀) are 3380. Results show that the influence of jet on wake structure is significant such that the wake region shrinks and the turbulent kinetic energy is enhanced as the velocity ratio increases. The distribution area of strong vorticity is enlarged with increasing velocity ratio. By using proper orthogonal decomposition and fast Fourier transfer analysis, the variation of velocity ratio demonstrates significant impact on vortex shedding and turbulent kinetic energy. The aerodynamic loss coefficient is nearly constant between VR = 0.5 and 1.0, but increases by 3.25 % as the velocity ratio increases from 1.0 to 1.5.     

钟板对液压悬置特性的影响

为揭示钟板数量对液压悬置特性影响,首先,根据液压悬置结构搭建解耦膜、节流盘以及新节流盘液压悬置数学模型,同时分析钟板数量对液压悬置动态特性影响;其次,在高低频状态分析钟板数量对惯性通道、解耦膜通道流量以及上腔压力响应的影响;最后,分析节流盘和新节流盘液压悬置在钟板处的流量和压力响应。计算表明:低频时3种液压悬置的动态特性几乎相同,随着钟板数量增加悬置动态刚度和滞后角略有减小;在节流盘液压悬置的基础上增加钟板不影响解耦膜通道流量和上腔压力响应,但影响悬置的刚度和滞后角。     

Dynamic and acoustic characteristics of bell type structure using finite element method

Dynamic and acoustic characteristics of the bell type structure were analyzed numerically. The finite element method with 3-D general shell element was used to identify the natural frequencies and mode shapes of the structure. Mode shapes and stress distributions of a transient dynamic analysis were effectively displayed by using computer graphic technique. The results of this numerical study were in good agreement with those obtained from the experimental test of fast Fourier transform analyer. Vibrational modes, which effect the acoustic characteristics of the typical bell-type structure were found to be the first flexural mode (4-0 mode) and the second flexural mode (6-0 mode). Asymmetric effects by Dangjwas and acoustic holes gave rise to beat frequencies, and the Dangjwa was found to be most effective. When the impact load was applied to the bell, the stress concentration occured at the rim part of the bell. It was found that the bell type structure should be designed thickly at the rim part in order to prevent failure from impact loads.     

Finite element simulation of nanoindentation tests using a macroscopic computational model

The aim of this work was to develop a numerical procedure to simulate nanoindentation tests using a macroscopic computational model. Both theoretical and numerical aspects of the proposed methodology, based on the coupling of isotropic elasticity and anisotropic plasticity described with the quadratic criterion of Hill are presented to model this behaviour. The anisotropic plastic behaviour accounts for the mixed nonlinear hardening (isotropic and kinematic) under large plastic deformation. Nanoindentation tests were simulated to analyse the nonlinear mechanical behaviour of aluminium alloy. The predicted results of the finite element (FE) modelling are in good agreement with the experimental data, thereby confirming the accuracy level of the suggested FE method of analysis. The effects of some technological and mechanical parameters known to have an influence during the nanoindentation tests were also investigated.     

Numerical Study of the Sensitivity of Tilting-Pad Journal Bearing Performance Characteristics to Manufacturing Tolerances: Dynamic Analysis

In engineering practice, the predictions of bearing steady state and the dynamic characteristics are based on the bearing nominal dimensions. However, as the authors showed in a previous study (Fillon, et al. (1) Fillon, M., Dmochowski, W. and Dadouche, A. 2007. Sensitivity of Tilting Pad Journal Bearing Performance Characteristics to Manufacturing Tolerances. Trib. Transactions, 50: 387–400. [Taylor & Francis Online], [Web of Science ®] , [Google Scholar]), manufacturing tolerances related to the bearing geometry (e.g., bearing clearances or angular pivot position) can significantly affect the steady-state characteristics such as the operating temperature, the minimum film thickness, and the power loss. This paper investigates changes to the bearing dynamic properties due to variations of the design parameters within the manufacturing tolerances. The dynamic properties of the tilting-pad journal bearings are represented by eight linear coefficients of stiffness and damping.

The study presents results obtained for realistic variations of bearing clearance, preload, pivot offset, as well as the pad angular extension. As an example, five-pad tilting-pad journal bearings with a diameter of 76.2 mm (3 in.) and three different L/d ratios have been used.     

Study on rock reaction force depending on PDC cutter placement

The article focuses on the problem of polycrystalline diamond cutter (PDC) cutters' overlapping influence on rock reaction force. This study proposed a static force balance model, based on the model of Wojtanowicz and Kuru (1993 Wojtanowicz, A.K.; Kuru, E. (1993) Mathematical modeling of PDC bit drilling process based on a single-cutter mechanics. Journal of Energy Resources Technology-Transactions of the ASME, 115(4): 247–256.[Crossref], [Web of Science ®] , [Google Scholar]). The innovation of this model is considering two types of friction forces, acting on the contact frontal surface and the lateral surface of a PDC cutter, respectively. Additionally, the proposed model assumes a rock reaction force direction not orthogonal to the contact surface of a cutter but parallel to the crack propagation direction and similar to the rock heterogeneity direction.

Numerical study was provided for a new and a worn PDC cutter to define a rock reaction force depending on options of adjacent cutters' placement (cutters' shape, cutter sizes, bake rake angle, side rake angle, etc.). Two main tendencies were observed: increasing of lateral plot of a cutter decreases rock reaction force, and deviation between directions of cutting force and crack propagation is an extremely significant factor and affects rock reaction force magnitude.     

Eco-innovative design approach: Integrating quality and environmental aspects in prioritizing and solving engineering problems

This study proposes an eco-innovative design process taking into consideration quality and environmental aspects in prioritizing and solving technical engineering problems. This approach provides a synergy between the Life Cycle Assessment (LCA), the nonquality matrix, the Theory of Inventive Problem Solving (TRIZ), morphological analysis and the Analytical Hierarchy Process (AHP). In the sequence of these tools, LCA assesses the environmental impacts generated by the system. Then, for a better consideration of environmental aspects, a new tool is developed, the non-quality matrix, which defines the problem to be solved first from an environmental point of view. The TRIZ method allows the generation of new concepts and contradiction resolution. Then, the morphological analysis offers the possibility of extending the search space of solutions in a design problem in a systematic way. Finally, the AHP identifies the promising solution(s) by providing a clear logic for the choice made. Their usefulness has been demonstrated through their application to a case study involving a centrifugal spreader with spinning discs.     

An ECRH control and data acquisition system on the gas dynamic trap

A control system for the electron cyclotron resonance heating (ECRH) complex installed on a gas dynamic trap (GDT) facility is described. The ECRH complex is based on two gyrotrons operating at a radiation frequency of 54.5 GHz with a total power of 0.9 MW and is intended for additional heating of the electron plasma component. The general structure of the complex is presented, and the requirements for control signals and parameter-measurement channels are considered. The control-system algorithm and the operator interface are realized using LabView 2010 for Linux. The required set of measurement and control channels is formed using programmable controllers. The developed system is presently used in experiments on microwave heating of plasma in the GDT facility.     

Numerical investigation for erratic behavior of Kriging surrogate model

Kriging model is one of popular spatial/temporal interpolation models in engineering field since it could reduce the time resources for the expensive analysis. But generation of the Kriging model is hardly a sinecure because internal semi-variogram structure of the Kriging often reveals numerically unstable or erratic behaviors. In present study, the issues in the maximum likelihood estimation which are the vital-parts of the construction of the Kriging model, is investigated. These issues are divided into two aspects; Issue I is for the erratic response of likelihood function itself, and Issue II is for numerically unstable behaviors in the correlation matrix. For both issues, studies for specific circumstances which might raise the issue, and the reason of that are conducted. Some practical ways further are suggested to cope with them. Furthermore, the issue is studied for practical problem; aerodynamic performance coefficients of two-dimensional airfoil predicted by CFD analysis. Result shows that such erratic behavior of Kriging surrogate model can be effectively resolved by proposed solution. In conclusion, it is expected this paper could be helpful to prevent such an erratic and unstable behavior.     

An analytical and experimental study of impulsive stress of square plates at an impact loading point by the 3-dimensional dynamic theory of elasticity

In this paper, a new method is proposed to analyze impulsive stresses at an impact loading point, which cannot be solved by the classical plate theory. Particularly, impulsive stresses at an impact loading point under any impact conditions (regardless of mass of impactor, velocity of impactor, stiffness of plate, etc.), can be obtained by the three-dimensional dynamic theory of elasticity and potential theory of displacement. In addition, by using the Hertzian contact theory, impact loading can be analyzed to account for the local deformation, and this load is applied to the impulsive stress analysis by approximating the impact loading to an analyzable function. In the numerical analysis, the Fourier transform (FFT) algorithm and the numerical inverse Laplace transformation are utilized. Using a new equation, it was possible to analyze impulsive stresses at an impact loading point, and good agreement between the experimental and theoretical results was established.     

The effect of high-dispersion fillers on adhesive and frictional properties of ethylene-vinyl acetate copolymer

The adhesive strength of adhesive joints between metal surfaces has been improved considerably by modifying an adhesive based on a copolymer of ethylene with montmorillonite vinyl acetate. It as been proved that the static (adhesive joint) and dynamic (frictional interaction) adhesion modes are correlated. It has been shown that the surface potential found by a modified Kelvin-Zisman method increases with increasing adhesion of the metal-polymer joint.     

Uncertainty evaluation procedure and intercomparison of bell provers as a calibration system for gas flow meters

Many NMIs (national measurement institutes) and calibration laboratories worldwide use a bell prover as a calibration system for gas flow meters. The basic definition and procedure to estimate the bell prover uncertainty have been given in previous studies. After the announcement of a mutual recognition agreement (MRA) in 1998 by the BIPM (Bureau International des Poids at Mesures), many NMIs have needed to have more details of uncertainty evaluation procedure of the bell prover. In this study, more details of the test procedure of bell prover uncertainty are presented with a modification of position of the temperature and the pressure sensor to measure more exact values. The other modification is to use three precise guide rods with bearings to make the pressure in the bell more stable. Furthermore, a laser interferometer is used to enhance the measurement accuracy of the testing time and the traveling length of the bell. The uncertainty of the bells estimated by the procedure given in this study is 0.13% at the confidence level of 95%, rather than 0.17% of the previous one. Recently, the results of CCM.FF-K6, which is an international comparison of NMIs organized by the CIPM (Comité International des Poids et Mesures), show that the uncertainty of the KRISS (Korea Research Institute of Standards and Science) bell prover estimated by this study is reasonable.