Optimisation of opportunistic maintenance of a multi-component system considering the effect of failures on quality and production schedule: A case study

For a manufacturing equipment, any unplanned breakdown during the production period results into a high production loss. To keep the manufacturing facilities in good condition, preventive maintenance is planned. However, because of limited time and availability of resources, not all the system components can be or need to be repaired/replaced during a planned opportunity. Hence, the unplanned breakdowns can also be considered as an opportunity to do the maintenance activities for other components to take the advantage of economic dependency in multi-component system. However, when the system is under maintenance, it is very conservative to take the decision of maintenance actions on the components because of limited available time and resources. For such situation, this paper consider an opportunistic maintenance model for a multi-component system to take maintenance decision with a constraint on available time and the system availability requirements. The maintenance decisions for each component involves one of the three actions namely, repair, replace or do nothing to achieve the target availability with minimum maintenance cost. The model also considers the effect of component failures on the quality of product being manufactured as well as the production schedule on the machine. The cost of rejections is considered in the total failure cost along with the maintenance and downtime costs. The production schedule delay factor is considered as a constraint for the maintenance decision to account for the effect on production schedule delay. The optimal solution for the model is obtained using three solution methodologies namely simulated annealing, genetic algorithm and sequence heuristics. Using a real-life example of high pressure die casting machine, the opportunistic maintenance approach is demonstrated and results are discussed.     

Properties of disturbance waves in vertical annular two-phase flow

Disturbance waves play an important role in interfacial transfer of mass, momentum and energy in annular two-phase flow. In spite of their importance, majority of the experimental data available in literature on disturbance wave properties such as velocity, frequency, wavelength and amplitude are limited to near atmospheric conditions (Azzopardi, B.J., 1997. Drops in annular two-phase flow. International Journal of Multiphase Flow, 23, 1-53). In view of this, air-water annular flow experiments have been conducted at three pressure conditions (1.2, 4.0 and 5.8 bar) in a tubular test section having an inside diameter 9.4 mm. At each pressure condition liquid and gas phase flow rates are varied over a large range so that the effects of density ratio, liquid flow rate and gas flow rate on disturbance wave properties can be studied systematically. A liquid film thickness is measured by two flush mounted ring shaped conductance probes located 38.1 mm apart. Disturbance wave velocity, frequency, amplitude and wavelength are estimated from the liquid film thickness measurements by following the statistical analysis methods. Parametric trends in variations of disturbance wave properties are analyzed using the non-dimensional numbers; liquid phase Reynolds number (Re_f), gas phase Reynolds number (Re_g), Weber number (We) and Strouhal number (Sr). Finally, the existing correlations available for the prediction of disturbance wave velocity and frequency are analyzed and a new, improved correlation is proposed for the prediction of disturbance wave frequency. The new correlation satisfactorily predicted the current data and the data available in literature.     

Ultrafine-grained steel fabricated using warm multiaxial forging: Microstructure and mechanical properties

Grain refinement of bulk metals using severe plastic deformation (SPD) is a popular approach to improve both strength and toughness. In this paper, grain refinement of steel processed by warm multiaxial forging (MAF) and its mechanical behavior has been investigated. Coarse-grained, plain low carbon steel was deformed using MAF at 500 °C. Microstructural evolution is characterized using electron backscattered diffraction and mechanical behavior has been studied. Fraction of low angle grain boundaries (LAB) is observed to increase with strain up to total engineering strain of 1.3 thereafter it starts decreasing whereas, high angle grain boundaries showed just the opposite trend. It appears that initially grain subdivision takes place with imposition of strain thereby increasing the fraction of LAB. After a critical strain these LAB transforms into the high angle boundaries (HAB). The initial coarser grains of average 30 μm size subdivided into grains of the size finer than 0.5 μm. This has been confirmed by TEM micrographs. Improved tensile strengths and hardness values are obtained after warm MAF.     

Microstructural study of iron nitride thin films deposited by ion beam sputtering

An amorphous iron nitride thin film was deposited using reactive ion beam sputtering of iron by a beam of argon and nitrogen ions. Nitrogen content in the film as determined from conversion electron Mössbauer spectroscopy (CEMS) and X-ray photoelectron spectroscopy (XPS) was FeN_0.7. The mass density of the film was calculated using energy-dispersive X-ray reflectivity (EDXRR) measurements and is found to be 6.0 gm/cm³. CEMS shows that the film is nonmagnetic in nature. Morphology of the film is obtained from atomic force microscopy (AFM). The surface roughness of the film does not increase appreciably beyond that of the substrate even after a deposition of 131 nm of material with these qualities the film is a good candidate for the multilayer superstructure of a nuclear Bragg monochromator of the type ⁵⁶FeN_0.7/⁵⁷FeN_0.7.     

DC magnetization studies in Nb/Fe superconducting multilayers

The behavior of superconducting transition temperature T_C in superconducting/ferromagnetic (S/F) multilayers as a function of different layer thicknesses and for varying magnetic moment μ_B of the F layer atoms is studied. Multilayer structures consist of five bilayers of constant superconducting Nb layer thickness of 400 Å and Fe of 6 and 24 Å each. The analysis of the magnetization data revealed that for t_Fe=6 Å, the Fe layer is non-magnetic. The interpretation of the observed T_C behavior is attributed to the change of the interaction of the cooper pairs with this layer at the onset of ferromagnetism for t_Fe=6 Å. The hysteresis curve recorded under isothermal conditions at 4.5 K for [Nb (400 Å)/Fe (6 Å)]₅ multilayers shows the usual M–H hysteresis behavior which is typical of a hard type-II superconductor exhibiting an irreversibility field H_irr of 3.5 kOe with substantial pinning at lower field. In addition, [Nb(400 Å)/Fe(6 Å)]₅ multilayer displays anomalous behavior in the form of paramagnetic peak in the superconducting state just below the transition temperature T_C=6.25 K.     

Fabrication of ZnO-functionalized polypyrrole microcomposite as a protective coating to enhance anticorrosion performance of low carbon mild steel

In the present work, PPy, ZnO, and polypyrrole/zinc oxide (PPy/ZnO) microcomposites (1, 2, and 5 wt%) were prepared and their properties have been tuned for anticorrosion applications on low carbon mild steel. The synthesized products: ZnO, PPy, and composites were characterized by various sophisticated analytical techniques such as XRD, FTIR, Raman, FESEM, EDX, UV–VIS, TGA, and BET. The band frequencies observed at 480 and 588 cm⁻¹ in FTIR spectrum correspond to stretching vibrations of Zn-O and N-H bonds, respectively, broadening of the bands in the composites indicate strong interactions between ZnO and PPy matrix. The potentiodynamic polarization study of PPy and PPy/ZnO composite was carried out in 3.5% NaCl solution to investigate the corrosion resistance efficiency. PPy/1 wt% ZnO (I_corr = 190 nA) composite coating on low carbon mild steel was observed to exhibit best corrosion protection property compared to PPy (121 μA), 2 and 5 wt% ZnO (242, 295 nA) composites. © 2019 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2019 , 136, 48319.     

Estimating cell loss rates in high-speed networks with leaky bucket controlled sources

This paper deals with high-speed networks, such as the ATM network, over which data is transferred in cells or packets. Results based on asymptotic analysis of stochastic fluid flow models imply that these networks would have to be run at very low utilization to satisfy the stringent performance requirement of very low cell loss rates. Recent papers have quantified that asymptotic approximations can be quite bad with even a modest number of users sending traffic into the network. In this paper it is shown that two more assumptions in the asymptotic analysis may lead to significant overestimation of the cell loss rates. The more significant of these is the use of the underlying exponential ON durations if sources are policed. The second and less significant is the assumption of an infinite buffer. A new approximate nalytic method is then developed for estimating the cell loss rate with sources policed by a leaky bucket type mechanism. This method focuses directly on the problem of measuring cell losses in the presence of many sources simultaneously bursting in a time period small enough to cause buffer overflow. It turns out to be highly accurate even with some rather drastic simplifying assumptions.