Cold forming processes: some examples of predictions and design optimization using numerical simulations

Predicting the behaviour of steel during a deformation process, and then under service conditions, is one of the main challenges in cold forming. The design of optimized forging schedules, by means of classical trial+errors procedures, has become increasingly heavy in terms of time and cost in a competitive environment. Simultaneously, the improvement of steel qualities requires the microstructure, constitutive behaviour and deformability to be known a priori regarding a targeted application. During the last few years, numerical simulations have become a very efficient tool to reach these goals.

In this paper, we give examples of innovating forging sequences developed by numerical simulations, including the investigation of damage in tools and forged parts. In case of specific processes with very determined geometry — such as wire drawing — we show how systematic numerical studies may lead to predictive models of force, local strains and residual stress…

However, reliable predictions from numerical simulations require reliable input data, including constitutive laws, friction conditions and propensity to ductile damage. These data must be characterized under realistic sollicitations. Typical cold forging loadings are indeed very severe: local strains up to 600%, strain rates locally greater than 1000 s⁻¹, and subsequently, plastic heating over 500°C.

To characterize the constitutive behaviour, the standard upset test between grooved dies is used along with an original methodology to derive the strain hardening curve from the experimental force-displacement recording. Tool elastic deformations, specimen strain heterogeneity… are taken into account. This enables a precise determination of the strain hardening curve up to about 100% of strain. The extrapolation of the flow stress to greater deformations is then very easy and reliable. Such a test can be performed under quasi-static and isothermal conditions (0.1 s⁻¹ but also adiabatic and rapid conditions (up to 10 s⁻¹). This procedure was adapted to a Pellini hammer, which enables very simple characterization at 800 s⁻¹. The comparison of all these flow curves lead to the formulation of an original constitutive model, which accounts for the effects of plastic heating, strain rate, dynamic aging…

In order to predict ductile fracture during the forging process, the most classical criteria were tested over a wide range of experimental loading conditions. None of them were general enough to solve all the cold forming problems. On the other hand, mesoscopic models describing the deformation of the metal matrix around inclusions or second phases have proved to be in good agreement with the various experimental observations. An original plasticity criterium, based on the recent works in porous plasticity theory, has been developed and already displays promising capabilities. Simple experimental procedures enable a reliable classification of steel qualities, heat treatments… in term of forgeability.

Finally, the friction problem is treated using different methodologies based on the forming process considered. For forging operations, a fine analysis of the force-displacement curves in direct extrusion stages may lead to a precise measurement of the friction coefficient under pressures from about 200 MPa up to 1000 MPa and for sliding rates between 1 and 100 mm/s. For wire drawing process, a model relying on an analytical approach using a significantly improved slice method has been developed: the comparison of the experimental drawing force and the predicted one gives the friction coefficient in industrial processing conditions (speed up to 5 m/s).     

Design considerations for highly efficient edge‐lit quantum dot displays

Quantum dots (QDs) are increasingly the technology of choice for wide color gamut displays. Two popular options to incorporate QDs into displays include on‐edge and on‐surface solutions. The opto‐mechanical design for an on‐edge QD solution including a LED light bar (“on‐edge QD light bar”) is more complex than the design for a standard white phosphor LED light bar. In this paper, we identify and investigate a range of design parameters for an on‐edge QD light bar, and we show that these parameters have significant influence on system efficiency and color uniformity. The effects of varying these parameters are explored through the use of a custom adjustable testbed and optical raytracing methods. Our testbed data demonstrate the inherent trade‐offs between efficiency and color uniformity and provide guidance for the design of high‐performing displays. The optical raytracing data demonstrate a good predictive capability and support the use of optical modeling methods for a detailed exploration of a wider range of design parameters.     

Development of a high pressure automated lag time apparatus for experimental studies and statistical analyses of nucleation and growth of gas hydrates

Nucleation in a supercooled or a supersaturated medium is a stochastic event, and hence statistical analyses are required for the understanding and prediction of such events. The development of reliable statistical methods for quantifying nucleation probability is highly desirable for applications where control of nucleation is required. The nucleation of gas hydrates in supercooled conditions is one such application. We describe the design and development of a high pressure automated lag time apparatus (HP-ALTA) for the statistical study of gas hydrate nucleation and growth at elevated gas pressures. The apparatus allows a small volume (≈150 μl) of water to be cooled at a controlled rate in a pressurized gas atmosphere, and the temperature of gas hydrate nucleation, T(f), to be detected. The instrument then raises the sample temperature under controlled conditions to facilitate dissociation of the gas hydrate before repeating the cooling-nucleation cycle again. This process of forming and dissociating gas hydrates can be automatically repeated for a statistically significant (>100) number of nucleation events. The HP-ALTA can be operated in two modes, one for the detection of hydrate in the bulk of the sample, under a stirring action, and the other for the detection of the formation of hydrate films across the water-gas interface of a quiescent sample. The technique can be applied to the study of several parameters, such as gas pressure, cooling rate and gas composition, on the gas hydrate nucleation probability distribution for supercooled water samples.     

Water Governance in Canada: Innovation and Fragmentation

This paper explores Canada's approach to water governance. It argues that fragmented governance has had negative impacts on Canada's ability to manage water resources adequately (particularly in the context of urbanization, agriculture and resource extraction), and to deal with new issues (such as climate change). Further, it argues that Canada's highly decentralized approach to water governance creates challenges of integration, coordination and data availability. The paper explores possible future strategies for innovations in water governance that may have the potential to improve water management outcomes.     

Issues in modified problem‐based learning: A self‐study in pre‐service science‐teacher education

Abstract:

In this self‐study, the author gained in‐depth understanding of how to plan and implement problem‐based learning (PBL), a student‐centred approach to teaching and learning that is driven by messy, open‐ended problems. This paper focuses primarily on the issues and concerns that arose as she developed and implemented a modified form of traditional PBL (Barrows, 1996) in large, pre‐service science‐teacher education classes. To view the research from many perspectives, a variety of data collection methods and sources were used, including field notes, semi‐structured interviews, student‐generated documents, and student journals. The outcomes of this study describe challenges (problem development, facilitation of groups, and assessment) encountered by the author as she planned for and implemented PBL. Furthermore, changes in the author's classroom practice, the connection between these changes and constructivist learning principles, and implications for science‐teacher education are addressed.     

Relationship between the attenuation of downwelling irradiance at 490 nm with the attenuation of PAR (400 nm-700 nm) in the Baltic Sea

The vertical attenuation coefficient of diffuse downwelling irradiance at 490 nm (K_d 490) is a parameter that we routinely derive from SeaWiFS images of the Baltic Sea. Here, through model simulations, we examine the relationship between K_d(490), and the vertical attenuation coefficient of PAR (K_d PAR), as this later coefficient determines the light available for aquatic photosynthesis. A simple semi-analytical model is used to predict K_d(490) and K_d(PAR), as a function of the concentrations of chlorophyll, colored dissolved organic material (CDOM), suspended inorganic, and suspended organic particulate material. A series of model simulations based on variations in these optically significant constituents over a range realistic for the Baltic Sea, are used to define the relationship between the two attenuation coefficients.

Kd(PAR)=0.6677Kd^0.6763(490).     

Lose Fat, Not Muscle: An Examination of Supervisor Reduction in Discrete-Event Systems

This paper is concerned with the elimination of unnecessary states in discrete-event system control agents. Several approaches to supervisor reduction are studied and a new relation between agents, comparability, is defined to encapsulate most of the concepts found in the aforementioned methods. This relation is also proven to be preserved under conjunction, which is commonly employed to determine the centralized representation of two decentralized DES supervisors.

Solutions of the general equations for the radiation dose dependence of the molecular weights of irradiated polymers with an initial Schulz-Zimm distribution

Summary The general equations for the radiation dose dependence of irradiated polymer molecular weights have been solved exactly. For an initial most probable molecular weight distribution (=1), the solutions are analytical and exact. For the general case (1) the solutions are numerical and exact. The present approach has resulted in the solutions for both =1 and 1 being incorporated into a group of FORTRAN computer programs which will solve experimental data for scission and crosslinking yields by both minimization and exact treatments. Simulated data treated using these FORTRAN programs are give. The FORTRAN programs are available from the authors.