Characteristics of forming presses and recent developments for precision and net shape forming

The trend in metal forming is to produce parts with increased precision and geometric complexity. Thus, research and development is being conducted worldwide to develop presses and tooling for near-net and net shape forming of difficult-to-form components. As a result, presses with increased precision and multi-action tooling are being used routinely by advanced companies around the world. This paper will discuss the interactions between press characteristics and part production in precision forming and review some of the new press and tooling designs recently developed by various domestic and foreign manufacturers.     

Estimating the quality of process yield by fuzzy sets and systems

Fuzzy grading is a multi-class problem, and is used for grading the product according to the degree of fitness for use, customer acceptance or commercial value. In this respect, the production system requires intelligent adjustments. Fuzzy set theory has a variety of applications in different fields. The most fruitful applications are in the field of modeling and control of production systems. Fuzzy logic may be used to control the key quality parameters, grade product quality to reduce the variations and adjust to the specification limits.Fuzzy grading expresses the quality level of product by membership degrees in which belonging or not-belonging to a quality set is gradual. Similarly, the quality control charts are also focused on the reduction of variability and grading the key quality characteristics. The control limits are used to establish the natural spread or range of process so the controller will not signal changes in the process until the natural limits are exceeded. However, there is a logical inconsistency in control chart approaches, due to their crisp grading nature which are expressed as either conforming (good) or nonconforming (poor) to specifications. In this study, a new fuzzy grading approach was developed based on a fuzzy expert system. The outcomes of the fuzzy grading system were clearly proven to be more vigorous and flexible than the crisp control methods.     

An Analytical Approach to the Concept of Counter-UA Operations (CUAOPS)

Unmanned Aircraft (UA) have become an integral part of the present-day joint air operations. UA have potential to be employed across the full spectrum of Air Force functions. On the other hand, UA technology could be a subject of an asymmetric use by state actors in high or low density conflict, and/or by non-state actors in many ways including terrorism, drug smuggling, and limited attack with unconventional payloads i.e. biological or chemical agents. Therefore countering the threat associated with the hostile UA use could be necessary in the future. First part of the research revealed that UA can be a threat in the future. In the second part of the research, the SWOT (Strengths-Weaknesses-Opportunities-Threats) analysis supplemented with the Tree analysis (SWOT+Tree) provided a broader look for investigating the factors related to hostile UA use analytically. In literature, there is little information about the concepts for CUAOPS. The final goal of the paper is to find possible solutions and means for a better understanding of the nature of CUAOPS.     

Process Modeling for Precision Forming of Discrete Parts – State of the Technology and Critical Issues

This paper presents an overview on the application of FE simulation as a virtual manufacturing tool in designing manufacturing processes for precision parts. The processes discussed include forging, sheet metal forming and hydroforming. Determination of reliable input parameters to simulate a process is a key element in successful application of process simulation for process design in all the mentioned areas. These issues are discussed in detail. Practical examples of application of FE simulation are presented for improvement of the existing metal forming process and/or designing new metal forming process for manufacturing discrete precision parts in forging, sheet metal forming and hydroforming.     

FLOW STRESS DATA FOR FINITE ELEMENT SIMULATION IN METAL CUTTING: A PROGRESS REPORT ON MADAMS

To obtain reliable results from Finite Element (FE) simulation of machining processes, it is necessary to have as input the properties of the workpiece and tool materials as well as the characteristics of the tool/chip interface. These input parameters include physical and thermal data, friction and heat transfer, and most importantly the flow stress of the workpiece material under high strain, strain rate and temperature conditions that exist during the process. This paper presents a brief review of FE simulation of machining processes, a review of the approaches used to determine the flow stress at high deformation rate, and the examples of different constitutive equations used to represent such flow stress data. A material property database (MADAMS) has been developed and provides useful information to conduct simulations of machining processes. The main objectives of the material database are to assist researchers in areas of machining analysis and material modeling and to promote collaboration between various international research groups.     

Investigation of Spin State Transition of [FeC<Subscript>17</Subscript>H<Subscript>31</Subscript>N<Subscript>7</Subscript>]<Superscript>2+</Superscript> Compound by Using the Density Functional Method

The symmetry of the [FeC₁₇H₃₁N₇]²⁺ novel compound is close to octahedral which has spin crossover properties (SCO). In this study, geometrical optimization, IR vibration frequencies, and HOMO-LUMO energy differences at various temperatures of the compound were calculated by DFT. It is realised that the computed splitting energies and splitting free enthalpies together with the mole fraction of HS state are compatible with the experiment.     

Towards occupant-centric simulation-aided building design: a case study

ABSTRACT

This paper aims at illustrating the importance of occupant modelling for decision-making during the building design process. It identifies the energy implications of conventional ways of modelling occupants for the design of office buildings. Furthermore, it presents a step towards bridging the gap between the research efforts and conventional practices within the field of building performance simulation (BPS) aided design. The paper first describes occupant-related assumptions that were made during the design process of a case study office building, obtained via stakeholder interviews. Then, the impact of these assumptions on the design decisions is examined through a simulation-based investigation. The stakeholder interviews revealed that professionals from each design discipline made significantly different assumptions about occupants. The simulation results showed that assumptions about occupants and their behaviour impacted predicted energy savings of some design decisions by a factor of five or more.     

Evaluation of pre-treatment processes for HRS (hot rolled steel) in powder coating

Hot rolled steel (HRS) is used extensively in the automotive, agricultural and appliance industries. The corrosive response of HRS was investigated after it had been exposed to various surface treatments, prior to powder coating. The behaviour of three conversion coatings: zinc phosphate (ZnP), iron phosphate (FeP) and zirconium (Zr)-based nano-scaled, on HRS was studied. HRS is naturally covered with iron oxide scale and this was removed from the surface by mechanical and chemical processes, prior to the application of surface treatment and organic coatings. The following tests on differently treated panels were conducted to evaluate corrosion performance: adhesion tests such as, crosshatch, pull-off, and conical bending, SEM, XPS, salt spray and electro-chemical impedance studies were also performed. Good correlations were recorded showing that zinc phosphate conversion coating gave the best performance, and zirconium-based nano-structured conversion coating, was superior to that of iron phosphate conversion coatings on HRS.     

Heat pipes thermoelectric solar collectors for energy applications

This study investigates the load characteristics of heat pipe thermoelectric solar collector (HPTSC) in practice. Heat pipe thermoelectric solar collector converts the heat generated by the Sun directly into electrical energy and produces hot water as well. The maximum power in HPTSC is obtained when the internal resistance of the thermoelectric module is equal to the load resistance. It has been observed to be possible to produce both hot water and electricity by improving available solar collectors or producing new generation HPTSC. While it is possible to generate an electrical power of 160 W from a HPTSC of one square meter using the thermoelectric method, the power produced with an average photovoltaic panel with the same area is only 132 W. Accordingly, HPTSC is a superior alternative not only to available solar collectors, but also to available PV panels. HPTSC, involving three different technologies, is environmentally friendly and certainly a product that allows for more efficient use of solar energy.