Numerical simulation of molten metal flow under vacuum condition in high pressure and low pressure die casting process

Abstract

The vacuum analysis algorithm was developed to simulate the total system of high pressure die casting process including vacuum vent, cavity and plunger area. The various vacuum degrees (760, 650, 500, 250 and 60 mmHg) were artificially applied in cavity. The filling behaviours of molten metal under the applied vacuum conditions were simulated and compared with those of experiment. The filling amount in cavity was increased with the increase of applied vacuum pressure during partial shot experiments. The simulated filling behaviours of molten metal were relatively well agreed with those of experiment. Through the results of fluid flow simulation, the relationship of filling length and filling velocity with the variation of vacuum pressure was analysed respectively. And it applied to a real die casting product and the internal gas quantity of product was significantly reduced by modification of vacuum gate system.     

Sounding Out Pharmaceutical Processes

High-resolution ultrasonic spectroscopy is a novel technique with enormous potential for analysis of a wide range of samples and processes. This technique is based on precision measurements of velocity and attenuation of acoustical waves at high frequencies propagating through materials. It allows fast at/on line measurements analysis of formulation consistency (composition, structure) of raw materials, ingredients and intermediates, process impurity analysis, particle sizing, batch to batch variation, stability assessment etc in pharmaceutical industry. The technology can be used for static fingerprint measurements or for dynamic analysis of systems. Optical transparency is not required as ultrasonic waves propagate through opaque samples. The analysis is fast and non-destructive. High-resolution ultrasonic spectrometers were developed, patented and brought to the market by Ultrasonic Scientific Ltd. and recognised with various international awards. These instruments require small sample volumes, down to 0.03 ml, and give excellent resolution. They can be used for the analysis of composition, aggregation, particle sizing, gelation, micellisation, crystallisation, sedimentation, enzymatic activity, conformational transitions in polymers, biopolymer-ligand binding and antigen-antibody interactions, etc. This article describes main features of High-Resolution Ultrasonic Spectroscopy and area of applications of new high-resolution HR-US series of ultrasonic spectrometers. Several applications are illustrated including the monitoring of denaturation and aggregation of proteins in antibody solution, the measurements of the particle size in emulsions, precipitation in synthetic blood substitutes and crystallisation     

Transport of large nuclear power plant components: experiences in mechanical design assessment

Abstract

In the course of decommissioning of power plants in Germany large nuclear components (steam generator, reactor pressure vessel) must be transported over public traffic routes to interim storage facilities, where they are dismantled or stored temporarily. Since it concerns surface contaminated objects or low specific activity materials, a safety evaluation considering the IAEA transport regulations mainly for industrial packages (type IP-2) is necessary. For these types of industrial packages the requirements from normal transport conditions are to be covered for the mechanical proof. For example, a free drop of the package from a defined height, in dependence of its mass, onto an unyielding target, and a stacking test are required. Since physical drop tests are impossible generally due to the singularity of such 'packages', a calculation has to be performed, preferably by a complex numerical analysis. The assessment of the loads takes place on the basis of local stress distributions, also with consideration of radiation induced brittleness of the material and with consideration of recent scientific investigation results. Large nuclear components have typically been transported in an unpackaged manner, so that the external shell of the component provides the packaging wall. The investigation must consider the entire component including all penetration areas such as manholes or nozzles. According to the present IAEA regulations the drop position is to be examined, which causes the maximum damage to the package. In the case of a transport under special arrangement a drop only in an attitude representing the usual handling position (administratively controlled) is necessary. If dose rate values of the package are higher than maximum allowable values for a public transport, then it is necessary that additional shielding construction units are attached to the large component.     

A New Digital Sense Multiple Access (DSMA) Protocol for High-Speed Wireless Networks

In this paper, we propose a new digital sensemultiple access with delayed transmission (DSMA/DT)protocol for reverse channel in high-speed wirelessnetworks. The new protocol is motivated by theobservation that the existing DSMA protocol does not yieldsatisfactory throughput for long round-trip propagationand processing delay, which occurs in outdoor high-speedenvironments or when the receiver hardware requires long signal processing time. The newDSMA/DT protocol is intended to reduce the performanceimpacts of the round-trip delay. Look-ahead busy/idleflag, seizure queueing, and reserved time slots are also devised for the new protocol. Whilerequiring at most two additional status bits on theforward channel and no additional hardware capability,these features further enhance the protocol performance and enable constant-bit-rate service withlittle added complexity in control. The channelthroughput of the DSMA/DT protocol and the optionalfeatures are analyzed. Closed-form expressions for thethroughput are obtained. For non-negligible round-tripdelay relative to packet transmission time, ournumerical results show that the new protocol improvesthe throughput by as much as 60% when compared to theexisting DSMA protocol. For superior performance andsimplicity, the DSMA/DT protocol will be appropriate foruse in high-speed wireless networks.     

Selective use of rubber toughening to optimize lap-joint strength

This paper introduces a novel approach to increasing the lap joint strength, different from the traditional methods of either increasing the lap joint area or altering the joint geometry. This is accomplished by the selective use of rubber toughening in epoxy to optimize lap joint strength. This was accomplished in three stages. In the first stage an adduct was prepared, this was used to make bulk tensile specimens to calculate the bulk properties for various concentrations of rubber, i.e. 0, 10, and 20 parts per hundred parts of resin (epoxy). In the second stage finite element models were developed using the bulk properties previously obtained. Interfacial stresses were used to access the trends obtained by the selective use of rubber toughening at different locations of the overlap in different configurations. The modeling of adhesive joints was done using ALGOR 2-D, linear and nonlinear finite element analyses (FEA). In the third stage, tensile shear tests conducted on the lap joints validated the trends from the finite element models. Finite element modeling and meshing of the lap joints having 25.4 and 50.8 mm adhesive overlap lengths were completed. Different configurations of rubber toughened and untoughened adhesive were tried in these two overlaps. The validation was done by lap joint tests conducted on an Instron mechanical tester coupled with an extensometer. Comparable strengths were obtained for completely toughened overlap and the configuration where only the edges of the adhesive overlap were toughened and the region in-between was untoughened. Also, the nonlinear FEA was shown to represent the experimental results more closely than the linear approach.     

Stress analysis and strength evaluation of bonded shrink fitted joints subjected to torsional loads

This paper deals with the stress analysis and strength evaluation of bonded shrink fitted joints subjected to torsion. The stress distributions in the adhesive layer of bonded shrink fitted joints are analyzed by the axisymmetric theory of elasticity when an external torsion is applied to the upper end of the shaft. The effects of the outer diameter and the stiffness of rings on the interface stress distributions are clarified by numerical calculations. Using the interface stress distributions, the joint strength is predicted. In addition, the joint strength was measured experimentally. It is seen that rupture of the adhesive layer is initiated from the upper edge of the interface when torsion is applied to the upper end of the shaft. The numerical results are in fairly good agreement with the experimental results. It was found that the joint strength of bonded shrink fitted joints is greater than that of shrink fitted joints.     

Effect of heating rate on dielectric and pyroelectric properties of double doped PZT

Abstract

Double doped lead zirconium titanate (PZT) was synthesised by solid state reaction method. Calcination and sintering was carried out at various heating rates in order to study the effect of heating rate on the extent of phase formation of double doped PZT. Furthermore, the effect of heating rate on dielectric and pyroelectric properties was also investigated. Rhombohedral perovskite phase was confirmed in the double doped PZT samples. Quantitative X-ray diffraction (XRD) analysis suggests that the extent of PZT formation decreases beyond 8°C min^?1 heating rate. The crystallite and grain sizes calculated from Scherrer's equation and field emission scanning electron microscope (FE-SEM) photographs respectively show the decreasing behaviour with increasing heating rate. Dielectric and pyroelectric properties show the increasing behaviour up to 8°C min^?1 and decreasing behaviour beyond this heating rate.     

New Equipment Materials And Techniques

Abstract

Holographic interferometry has been applied to in situ measurements of vibration fields of large diameter conduits undergoing unsteady internal excitations. The ambient conditions under which the measurements were carried out were extremely difficult. The measurements, covering an area of several square meters with each holographic recording, were performed using a portable one joule pulsed ruby laser system capable of producing two sequential Q-switched pulses each with duration of ～25 ns with a variable pulse separation between 10 and 800 μs. The entire assembly of laser and holographic camera was constructed as a single unit incorporating an internal reference beam; the reference beam included a mirror with the facility to make an angular tilt between the two laser pulses with the objective of providing a facility to obtain information relating to the phase of antinodes within the recorded area of the hologram.     

Non-isothermal thermomechanical metallurgical model and its application to welding simulations

Abstract

This paper presents a thermomechanical metallurgical macroscopic model for steels. The model is based on an existing model that is extended for non-isothermal behaviour in combination with phase transformations. The model and its numerical implementation in ABAQUS are described using vector notation for stress and strain tensors. Model parameters are presented for the dual phase steel DP600 and the structural steel S355. For DP600, thermomechanical model parameters, i.e. hardening and strain rate dependency, have been obtained by fitting temperature and strain rate dependent tensile tests. A metallurgical model was implemented using data obtained from phase field models for the austenite growth and continuous cooling transition diagrams for phase transformations from austenite to low temperature phases. The model is applied to welding simulations of DP600 overlap joints and S355 T joints. The final distortion is compared to experiments and it is shown that the model presented is able to reproduce the experimental results very well.     

Mechanical and fatigue behaviour of laser and resistance spot welds in advanced high strength steels

Abstract

A study was carried out on laser and resistance spot welds in overlapped sheets of dual phase advanced high strength steel (DP780) and deep drawing steel (DC04) of 2˙0 mm in thickness. The aim of the study was to investigate the fatigue performance of these joints under tensile shear loading as well as the monotonic performance for applications in the automotive industry. The mechanical properties, failure behaviour and fatigue life analyses of spot welds in similar and dissimilar joints were investigated by experimental and numerical methods. The structural stress concept was used to describe the fatigue lives of spot welded specimens. The results revealed different failure types with different fatigue behaviours for laser and resistance spot welds under the application of cyclic loads at 'high load' and 'low load' levels.