Finite element simulation of the manufacturing process chain of a sheet metal assembly

An increasing number of components in automotive structures are today made from advanced high strength steel (AHSS). Since AHSS demonstrates more severe springback behaviour than ordinary mild steels, it requires more efforts to meet the design specification of the stamped parts. Consequently, the physical fine tuning of the die design and the stamping process can be time consuming. The trial-and-error development process may be shortened by replacing most of the physical try-outs with finite element (FE) simulations of the forming process, including the springback behaviour. Still it can be hard to identify when a stamped part will lead to an acceptable assembly with respect to the geometry and the residual stress state. In part since the assembling process itself will distort the components. To resolve this matter it is here proposed to extend the FE-simulation of the stamping process, to also include the first level sub-assembly stage. In this study a methodology of sequentially simulating each step in the manufacturing process of an assembly is proposed. Each step of the proposed methodology is described, and a validation of the prediction capabilities is performed by comparing with a physically manufactured assembly. The assembly is composed of three sheet metal components made from DP600 steel which are joined by spot welding. The components are designed to exhibit severe springback behaviour in order to put both the forming and subsequent assembling simulations to the test. The work presented here demonstrates that by using virtual prototyping it is possible to predict the final shape of an assembled structure.     

Nanocrystalline-diamond thin films with high pH and penicillin sensitivity prepared on a capacitive Si-SiO2 structure

A capacitive field-effect EDIS (electrolyte-diamond-insulator-semiconductor) sensor with improved pH and penicillin sensitivity has been realised using a nanocrystalline-diamond (NCD) film as sensitive gate material. The NCD growth process on SiO₂ as well as an additional surface treatment in oxidising medium have been optimised to provide high pH-sensitive, non-porous O-terminated films without damage of the underlying SiO₂ layer. The surface morphology of O-terminated NCD thin films and the layer structure of EDIS sensors have been studied by scanning electron microscopy (SEM) and transmission electron microscopy (TEM) methods. To establish the relative coverage of the surface functional groups generated by the oxidation of NCD surfaces, X-ray photoelectron spectroscopy analysis was carried out. The hydrophilicity of NCD thin films has been studied by water contact-angle measurements. A nearly Nernstian pH sensitivity of 54-57 mV/pH has been observed for O-terminated NCD films treated in an oxidising boiling mixture for 80 min and in oxygen plasma. The high pH-sensitive properties of O-terminated NCD have been used to develop an EDIS-based penicillin biosensor. A freshly prepared penicillin biosensor possesses a high sensitivity of 85 mV/decade in the concentration range of 0.1-2.5 mM penicillin G. The lower detection limit is 5 μM.     

Modeling an industrial energy system: Perspectives on regional heat cooperation

Through energy efficiency measures, it is possible to reduce heat surplus in the pulp and paper industry. Yet pulp and paper mills situated in countries with a heat demand for residential and commercial buildings for the major part of the year are potential heat suppliers. However, striving to utilize the heat within the mills for efficient energy use could conflict with the delivery of excess heat to a district heating system. As part of a project to optimize a regional energy system, a sulfate pulp mill situated in central Sweden is analyzed, focusing on providing heat and electricity to the mill and its surrounding energy systems. An energy system optimization method based on mixed integer linear programming is used for studying energy system measures on an aggregated level. An extended system, where the mill is integrated in a regional heat market (HM), is evaluated in parallel with the present system. The use of either hot sewage or a heat pump for heat deliveries is analyzed along with process integration measures. The benefits of adding a condensing unit to the back-pressure steam turbine are also investigated. The results show that the use of hot sewage or a heat pump for heat deliveries is beneficial only in combination with extended heat deliveries to an HM. Process integration measures are beneficial and even increase the benefit of selling more heat for district heating. Adding a condensing turbine unit is most beneficial in combination with extended heat deliveries and process integration. Copyright © 2007 John Wiley & Sons, Ltd.     

Numerical modeling of a complex diffuser in a room with displacement ventilation

A micro/macro-level approach (MMLA) has been proposed which makes it possible for HVAC engineers to easily study the effect of diffuser characteristics and diffuser placement on thermal comfort and indoor air quality. In this article the MMLA has been used to predict the flow and thermal behavior of the air in the near-zone of a complex low-velocity diffuser. A series of experiment has been carried out to validate the numerical predictions in order to ensure that simulations can be used with confidence to predict indoor airflow. The predictions have been performed by means of steady Reynolds Stress Model (RSM) and the results have good agreement both qualitatively and quantitatively with measurements. However, measurements indicated that the diffusion of the velocity and temperature was to some extent under-predicted by the RSM, which might be related to high instability of the airflow close to the diffuser. This effect might be captured by employing unsteady RSM. The present study also shows the importance of detailed inlet supply modeling in the accuracy of indoor air prediction.     

Investigation of energy performance of newly built low-energy buildings in Sweden

Energy use in the built environment represents a large part of total energy use in Sweden and is one important sector where energy conservation needs to be significantly improved in order to meet the national implementation of the European goals. One key question that needs to be investigated in relation to these goals is the performance and implementation of passive or low-energy houses. This paper presents results and an evaluation of a newly built house in an area with passive houses in Linköping, Sweden. Nine passive houses were built with the aim to be energy efficient, with an annual space heating demand of 21 kWh/m², and at the same time to have the same visual appearance as any other building in the surrounding area.This study evaluates the energy performance of a residential area with low-energy buildings based on Building Energy Simulation (BES) (IDA ICE 4), and measurements from the real object. Both annual and hourly validation is performed using room by room modeling and internal heat gains. A novel approach to internal heat gain modeling is presented using time-use data (TUD). The results show possible improvements in the design, the building envelope and in the heating control.     

Estimation of process parameter variations in a pre-defined process window using a Latin hypercube method

The aim of this paper is to present a methodology that provides an analytical tool for estimation of robustness and response variation within a pre-defined process window. To exemplify the developed methodology, the stochastic simulation technique is used for a sheet-metal forming application. A sampling plan based on the Latin hypercube sampling method for variation of design parameters is utilized, and the thickness reduction is specified as the response. Moreover, the response surface methodology is applied for understanding the quantitative relationship between design parameters and response value. The conclusions of this study are that the applied method gives a possibility to illustrate and interpret the variation of the response versus a design parameter variation. Consequently, it gives significant insights into the usefulness of individual design parameters. It has been shown that the method enables us to estimate the admissible design parameter variations and to predict the actual safe margin for given process parameters. Furthermore, the dominating design parameters can be predicated using sensitivity analysis, and this in its turn clarifies how the reliability criteria are met. Finally, the developed software can be used as an additional module for set-up of stochastic finite element simulations and to collect the numerical results from different solvers within different applications.     

Modelling and optimization of district heating and industrial energy system—an approach to a locally deregulated heat market

Regions with densely concentration of industries and district heating systems (DHS) could be interesting study object from the light of an integrated heat market on local basis. System analysis with a widened system boundary could be used as an approach to evaluate the benefit of an integrated heat supply system. In this study, an energy system model consisting of totally seven different participants is designed and the optimization results of the system analysis are presented. With applied data and assumptions, the study shows that a significant amount of the heat demand within two sub‐systems can be covered by heat supply from the heat market (the entire heat comes from two industries). Shadow prices, which can be used for heat pricing, indicate the advantage of an integrated system. The system cost reduction through integration and the availability of several actors with diverse energy supply system, makes the region under study an interesting area to prove a locally deregulated heat market. Copyright © 2004 John Wiley & Sons, Ltd.     

Implementation of Ag nanoparticle incorporated WO3 thin film photoanode for hydrogen production

WO₃ thin film photoanodes containing different concentrations of Ag nanoparticles were synthesized by sol–gel method. Based on UV-visible spectra, presence of a surface plasmon resonance peak at 470 nm of wavelength indicated formation of silver nanoparticles in the WO₃ films. According to atomic force microscopy (AFM) analysis, the highest value for surface roughness and the effective surface ratio was observed for the sample containing 2 mol% of Ag. X-ray diffraction (XRD) patterns revealed that WO₃ nanocrystalline structure was formed in the monoclinic phase with the average size of about 18.2 nm while Ag nanocrystals were determined in cubic phase. X-ray photoelectron spectroscopy (XPS) showed that Ag exists in a combination of metal/oxide states on the surface. Photoresponse investigation of the synthesized films indicated that the highest photocurrent was obtained for the sample containing 2 mol% Ag with the maximum incident photon to current efficiency (IPCE) of about 20% at 360 nm wavelength. Moreover, measuring the amount of hydrogen produced during water splitting reactions verified that the highest hydrogen production rate (∼3 μmol/h) was obtained for the sample with 2 mol% Ag.     

Visible light active Au:TiO2 nanocomposite photoanodes for water splitting: Sol–gel vs. sputtering

In this study, pure TiO₂ and Au:TiO₂ nanocomposite thin films are both synthesized using sol–gel and RF reactive co-sputtering methods. Physical and photoelectrochemical properties of the thin films deposited by each method are compared. The optical density spectra and scanning electron microscopy images of the Au:TiO₂ films reveal formation of gold nanoparticles in the all nanocomposite films synthesized by two methods. Moreover, the optical bandgap energy of the thin films decreases with addition of Au nanoparticles. X-ray photoelectron spectroscopy indicates that the presence of gold in metallic state and the formation of TiO₂ is stoichiometric. The photoelectrochemical properties of the TiO₂ and Au:TiO₂ thin films are characterized by using a compartment cell containing KOH solution as electrolyte. It is found that in the pure systems, TiO₂ sputtered films shows a higher photocurrent under visible light illumination while a reverse result is obtained for the Au:TiO₂ systems. In addition, photoirradiation on electrode/electrolyte (EE) and substrate/electrode (SE) interfaces for the sputtered samples reveals the EE illumination enhances the photoresponse of the layers as compared to SE case.     

Reliability analysis of a sheet metal forming process using Monte Carlo analysis and metamodels

The aim of the present paper is to evaluate the use of linear and quadratic approximating response surfaces as metamodels in a reliability assessment of a sheet metal forming process using the Monte Carlo simulation technique. Monte Carlo simulation was used to determine the probability for springback and thickness variation in a sheet metal part. The conclusions of this study is that Monte Carlo analysis can be used to identify the most important variables and to estimate the range of the studied responses. Linear metamodels can be used to identify the important variables and to give an estimate of the probabilistic response. But quadratic surfaces are required for a more accurate analysis.