On the evaluation of the global heat transfer coefficient in cutting

The use of numerical simulations for investigating machining processes is remarkably increasing because of the simulation cost is lower than the experiments and the possibility to analyze local variables such as pressures, strains, and temperatures is allowable. Process simulation is very hard from a computational point of view, since it frequently requires remeshing phases and very small time steps. As a consequence, the simulated cutting time is usually of the order of few milliseconds and no steady cutting conditions are generally achieved, at least as far as thermal conditions are concerned. Therefore, nowadays numerical prediction of cutting temperatures cannot be considered fully reliable. In the paper this issue was taken into account: a mixed Lagrangian-Eulerian numerical approach was utilized and the global heat transfer (film) coefficient at the tool-chip interface was derived through an inverse approach. Finally, the dependence of the film coefficient on pressure and temperature on the rake face was investigated.     

A critical analysis on the friction modelling in orthogonal machining

Despite the development of high performance finite element-based codes, the simulation of machining still represents a very hard task due to the geometric complexity of the real chip-tool systems and the high cutting speed that requires very long simulation times. For these reasons, many aspects related to machining are not very clear and so easy to simulate. In this paper a rigorous investigation on the role played by the implemented friction model within a 2D simulation of orthogonal cutting was carried out, taking into account different models proposed by the researchers in the last years. The main simulation results were compared with experimental measurements in order to verify if it is possible to identify the best model. Once the comparison with mechanical variables was completed, a subsequent study on temperature predictions utilizing the above friction models was executed as well. The results of this integrated numerical and experimental work are carefully reported in the paper.     

Simulation of wave propagation in three-dimensional random media

Quantitative error analyses for the simulation of wave propagation in three-dimensional random media, when narrow angular scattering is assumed, are presented for plane-wave and spherical-wave geometry. This includes the errors that result from finite grid size, finite simulation dimensions, and the separation of the two-dimensional screens along the propagation direction. Simple error scalings are determined for power-law spectra of the random refractive indices of the media. The effects of a finite inner scale are also considered. The spatial spectra of the intensity errors are calculated and compared with the spatial spectra of intensity. The numerical requirements for a simulation of given accuracy are determined for realizations of the field. The numerical requirements for accurate estimation of higher moments of the field are less stringent.     

Local Effects Induced by Longitudinal Forces in Composite Girders

Local effects on the shear connection of composite girders induced by longitudinal actions such as the anchorages of prestressing cables, concrete shrinkage, or a uniform thermal action on the slab are analyzed. Closed-form solutions are obtained by using the simple model of a composite beam with a linearly elastic shear connection. Successively, by considering the limit scheme of an infinitely long beam, very simple formulas are derived permitting evaluation of the peak value and extension of the interface shear force distribution induced by the longitudinal actions. Numerical applications are carried out to show the effectiveness of the proposed formulas for a wide range of the shear connection stiffness and for longitudinal forces applied both along the beam axis and at the beam end.     

The Role of Higher Lying Electronic States in Charge Photogeneration in Organic Solar Cells

The role of excess photon energy on charge generation efficiency in bulk heterojunction solar cells is still an open issue for the organic photovoltaic community. Here, the spectral dependence of the internal quantum efficiency (IQE) for a poly[2,6‐(4,4‐bis‐(2‐ethylhexyl)‐4H‐cyclopenta[2,1‐b;3,4‐b]­dithiophene)‐alt‐4,7‐(2,1,3‐benzothiadiazole)]:6,6‐phenyl‐C₆₁‐butyric acid methyl ester (PCPDTBT:PC60BM)‐based solar cell is derived combining accurate optoelectronic characterization and comprehensive optical modeling. This joint approach is shown to be essential to get reliable values of the IQE. Photons with energy higher than the bandgap of the donor material can effectively contribute to enhance the IQE of the solar cell. This holds true independently of the device architecture, reflecting an intrinsic property of the active material. Moreover, the nanomorphology of the bulk heterojunction plays a crucial role in determining the IQE spectral dependence: the coarser and more crystalline, the lesser the gain in IQE upon high energy excitation.     

Innovative metamodelling-based process design for manufacturing: an application to Incremental Sheet Forming

The use of metamodelling techniques in process design has become indispensable to perform faster solutions reducing time to market. This approach allows the implementation of decision support tools which are easier to use than the conventional numerical simulations. In this paper, a robust metamodelling technique has been designed and its feasibility has been validated for the crucial problem of localised thinning in sheet metal forming process. The proposed methodology is based on the innovative integration between the Design of Experimental statistical method and the Kriging one. This approach, in fact, allows to analyse contemporary the continuous and categorical factors and, as a consequence, to define a single tool for changing process conditions (i.e., material and product shape). To test the reliability of the mathematical approach, the same was performed for the case study of Incremental Sheet Forming, a process strongly affected by the not homogeneous distribution of the thickness. Taking advantage of this strategy, a wide experimental investigation has been performed to build the base of knowledge of the problem both for the metamodelling design and for the validation of the decision support tool; moreover, the experimental data were utilized to set and validate a numerical model, which was subsequently used to enrich the dataset. The proposed metamodel, suitably modified according to each process peculiarities, can be generally adapted for sheet thickness prediction.     

On the high-speed Single Point Incremental Forming of titanium alloys

Single Point Incremental Forming processes show some limitations related to both dimensional accuracy and process slowness. The process slowness is here overcome by introducing the high speed forming, which allows a reduction to less than 1 min of execution time of target components made in Titanium alloys. The paper is aimed at analyzing the influence of the feed increasing on the material quality in order to investigate if the development of high speed machines could be a suitable solution to implement more extensively the Single Point Incremental Forming technique in practice.     

On the use of Back-drawing Incremental Forming (BIF) to improve geometrical accuracy in sheet metal parts

Industrial interest about Incremental Sheet Forming (ISF) process is growing in the last years. Up to a few years ago, two main investigation ways were proposed, the former aimed at analysing the process mechanics, the latter at reproducing some ??case study?? geometries. In industrial applications, if the long cycle-time can be neglected in small batches manufacturing, geometrical accuracy represents a relevant drawback, especially when the product has to be coupled to one another. For this reason, in the opinion of the authors, the low accuracy is the most relevant defect of ISF processes today. Among the techniques already set-up to reduce inaccuracy, the use of different material supports or the use of ??arbitrarily modified?? tool trajectories are probably the most known. In this paper a simple approach is proposed, based on the process self capability to correct inaccuracy when different steps of Incremental Sheet Forming are carried out on both the part surfaces. In particular, it is demonstrated that a relevant increasing in accuracy is obtainable at the second repeated step, while new ones do not reduce the inaccuracy sensitively. The above approach builds a new scenario since it allows to keep the basic equipment (without any support) and does not require any further knowledge concerning the material behaviour after the punch action. These aspects are deeply discussed in the next chapters.     

The ITER radial neutron camera: An updated neutronic analysis

The radial neutron camera (RNC) will provide the spatial distribution and the total strength of the ITER neutron source (emissivity profile and fusion power) by means of collimated neutron measurements. Line-integrated neutron spectral measurements can also provide information on the ion temperature profile. The present design of the RNC consists of two collimating structures for a full coverage of the plasma: 36 collimated lines of sight (LOS) distributed in three different planes view the plasma core (ex-port system) and nine collimated LOS view the plasma edge (in-port system).The RNC design is based on the combined use of the MCNP Monte Carlo code and a software tool performing asymmetric Abel inversion of simulated measured neutron signals (MSST). Neutron and γ-ray transport calculations are performed with MCNP using a 3D RNC model to determine the signal/noise for each RNC channel and the spectra at the detectors. The MSST code is used to check the RNC compliance with the ITER measurement requirements for the neutron emissivity profile.In the present paper the improvement of the hard variance reduction technique applied to the MCNP neutron source (consisting in sampling neutrons only from plasma regions contributing to the detector signal) is presented and the following issues are analyzed: the possibility of reducing the length of the ex-port collimators (resulting in a significant reduction of the overall RNC dimension and weight); options for the reduction of the dose due to the neutron streaming through the RNC cut-outs in the blanket shielding module; the integration of a γ-ray detection system in the RNC by partially filling the collimators with a neutron absorbing material (LiH).