Three-dimensional analysis of shape rolling using a generalized upper bound approach

A generalized analytical method has been proposed to study external shape and calculate pressure and torque for the process of rolling shaped sections. The proposed method is based on the upper bound analysis. To determine kinematically admissible velocity fields, flow lines have been mathematically formulated using the parameterization of curves. Based on the calculated velocity fields, an upper bound has been found on rolling power. The calculated power has been minimized with respect to unknown variables to yield the value closest to the actual power required.The proposed general method has been applied to certain rolling passes including square-to-oval and round-to-oval. Velocity fields and power relations have been obtained for each process. Computer analysis has been carried out for all the mentioned passes using dimensions and conditions from experiments conducted by other workers. External shape, average roll torque and average rolling pressure results from the analysis have been compared with analytical solutions, numerical analyses and experimental data presented by other workers. It was concluded that the present method gave very good results and was quicker and easier to use.     

Auxiliary input design for stochastic subspace-based structural damage detection

This paper considers the problem of auxiliary input design for subspace-based fault detection methods. In several real applications, particularly in the damage detection of mechanical structures and vibrating systems, environment noise is the only input to the system. In some applications, white noise produces low quality output data for the subspace-based fault detection method. In those methods, a residual is calculated to detect the fault based on the output information. However, some modes of the system may not influence the outputs and the residual appropriately if the input is not exciting enough for those modes. In this paper, the method of “rotated inputs” is implemented to excite the system modes. In addition to produce a residual more sensitive to the weak modes, it is possible to detect system order changes due to the fault using the rotated inputs. Simulation results demonstrate the efficiency of injecting the auxiliary input to improve the subspace-based fault detection methodology.     

Design of conical DRH antennas for K and Ka frequency bands

Two conical double‐ridged horn (DRH) antennas for K and Ka frequency bands are presented. Detailed simulation and experimental investigations are conducted to understand their behaviors and optimize for broadband operation. The designed antennas were fabricated with 0.01 mm accuracy and satisfactory agreement of computer simulations and experimental results was obtained. The designed conical DRH antennas have voltage standing wave ratio (VSWR) less than 2.1 and 2.2 for the frequency ranges of 18–26.5 GHz (K band) and 26.5–40 GHz (Ka band), respectively. Meanwhile, the proposed antennas exhibit low cross‐polarization, low sidelobe level, and simultaneously achieve slant polarization as well as symmetrical radiation patterns in the entire operating bandwidth. An exponential impedance tapering is used at the flare section of the horns. Moreover, a new cavity back with a conical structure is used to improve the VSWR. Numerous simulations via Ansoft HFSS and CST Microwave Studio CAD tools have been made to optimize the VSWR performance of the designed antennas. Simulation results show that the VSWR of the proposed antennas is sensitive to the probe spacing from the ridge edge and the cavity back structure. The designed conical DRH antennas are most suitable as a feed for the reflectors of radar systems and satellite applications. Results for VSWR, far‐field E‐plane and H‐plane radiation patterns, and gain of the designed antennas are presented and discussed. © 2011 Wiley Periodicals, Inc. Int J RF and Microwave CAE, 2011.     

Optimal design of laser solid freeform fabrication system and real-time prediction of melt pool geometry using intelligent evolutionary algorithms

With the rapid growth of laser applications and the introduction of high efficiency lasers (e.g. fiber lasers), laser material processing has gained increasing importance in a variety of industries. Among the applications of laser technology, laser cladding has received significant attention due to its high potential for material processing such as metallic coating, high value component repair, prototyping, and even low-volume manufacturing. In this paper, two optimization methods have been applied to obtain optimal operating parameters of Laser Solid Freeform Fabrication Process (LSFF) as a real world engineering problem. First, Particle Swarm Optimization (PSO) algorithm was implemented for real-time prediction of melt pool geometry. Then, a hybrid evolutionary algorithm called Self-organizing Pareto based Evolutionary Algorithm (SOPEA) was proposed to find the optimal process parameters. For further assurance on the performance of the proposed optimization technique, it was compared to some well-known vector optimization algorithms such as Non-dominated Sorting Genetic Algorithm (NSGA-II) and Strength Pareto Evolutionary Algorithm (SPEA 2). Thereafter, it was applied for simultaneous optimization of clad height and melt pool depth in LSFF process. Since there is no exact mathematical model for the clad height (deposited layer thickness) and the melt pool depth, the authors developed two Adaptive Neuro-Fuzzy Inference Systems (ANFIS) to estimate these two process parameters. Optimization procedure being done, the archived non-dominated solutions were surveyed to find the appropriate ranges of process parameters with acceptable dilutions. Finally, the selected optimal ranges were used to find a case with the minimum rapid prototyping time. The results indicate the acceptable potential of evolutionary strategies for controlling and optimization of LSFF process as a complicated engineering problem.     

A practical eco-environmental distribution network planning model including fuel cells and non-renewable distributed energy resources

This paper presents a long-term dynamic multi-objective planning model for distribution network expansion along with distributed energy options. The proposed model optimizes two objectives, namely costs and emissions and determines the optimal schemes of sizing, placement and specially the dynamics (i.e., timing) of investments on distributed generation units and network reinforcements over the planning period. An efficient two-stage heuristic method is proposed to solve the formulated planning problem. The effectiveness of the proposed model is demonstrated by applying it to a distribution network and comparing the simulation results with other methods and models.     

Reuse of waste sludge from papermaking process in cement composites

Papermaking sludge (PS), a waste residue from the pulp and paper processing, has brought great pressure on the environment because of large quantities that are produced in paper mills. This work was carried out to explore the possibility of making PS/cement composite products using solid waste of PS. Boards measuring 350 × 270 × 12 mm³ were manufactured using PS contents of 40, 50, and 60 wt%, adhesive dosages of 0, 10, and 15 wt%, and 0 and 5 wt% of calcium chloride as an accelerator. At least three replications were fabricated for each treatment, and some mechanical and physical properties of the boards were evaluated. Test results showed that the bending and internal strengths of the specimens decreased with an increase in the PS content, and the maximum values were obtained at PS loading of 40 wt%. The negative influence of PS content on the mechanical properties can be explained by the reduced bonding ability because of weaker PS compared with cement. Screw withdrawal values were up to 22.7 kPa. Water absorption and thickness swelling of cement mortar considerably increased with increased content of PS, with a corresponding reduction of bulk density. In general, all properties of the boards were improved when the adhesive and calcium chloride contents were increased. The results showed that an increase in board density improved the mechanical and physical properties. Finally, results showed that PS has good potential for recycling and utilization in developing value‐added building components. POLYM. ENG. SCI., 2013. © 2012 Society of Plastics Engineers     

Performance properties of microcrystalline cellulose as a reinforcing agent in wood plastic composites

Polypropylene (PP)/microcrystalline cellulose (MCC)/wood flour composites were prepared containing polypropylene-graft-maleic anhydride (PP-g-MA) as compatibilizer. The mechanical, morphological and thermal properties were investigated. The weight ratio of the cellulosic materials to polymer matrix was 40:60 (w:w). The obtained results showed that tensile, flexural and impact strengths of the composites were significantly enhanced with addition of MCC, as compared with pure PP and composites without MCC. The effect of MCC on impact was minimal compared to the effects of PP-g-MA content. Scanning electron microscopy has shown that the composite, with compatibilizer, promotes better fiber–matrix interaction. In all cases, the degradation temperatures shifted to higher values after addition of PP-g-MA. The maximum improvement on the thermal stability of the composites was achieved when 5% PP-g-MA was used. However, the increase in MCC content substantially reduced the thermal stability. This work showed that MCC along with wood flour could be effectively used as reinforcing agent in thermoplastic matrix.