Soft sensor for real-time cement fineness estimation

This paper describes the design and implementation of soft sensors to estimate cement fineness. Soft sensors are mathematical models that use available data to provide real-time information on process variables when the information, for whatever reason, is not available by direct measurement. In this application, soft sensors are used to provide information on process variable normally provided by off-line laboratory tests performed at large time intervals. Cement fineness is one of the crucial parameters that define the quality of produced cement. Providing real-time information on cement fineness using soft sensors can overcome limitations and problems that originate from a lack of information between two laboratory tests. The model inputs were selected from candidate process variables using an information theoretic approach. Models based on multi-layer perceptrons were developed, and their ability to estimate cement fineness of laboratory samples was analyzed. Models that had the best performance, and capacity to adopt changes in the cement grinding circuit were selected to implement soft sensors. Soft sensors were tested using data from a continuous cement production to demonstrate their use in real-time fineness estimation. Their performance was highly satisfactory, and the sensors proved to be capable of providing valuable information on cement grinding circuit performance. After successful off-line tests, soft sensors were implemented and installed in the control room of a cement factory. Results on the site confirm results obtained by tests conducted during soft sensor development.     

Assessment of spray quality from an external mix nozzle and its impact on SQL grinding performance

Spray quality is the critical factor which decides the efficacy of Small Quantity Lubrication (SQL) technology in a high specific energy involved machining process like grinding. Yet, the understanding about spray quality, the actual process mechanics and its effect on machining performance is inadequate. The present work is an attempt to establish a correlation between the spray input variables, quality of the spray and machining performance of SQL grinding through modelling and experiments. Using computational fluid dynamic techniques, the variation of droplet size, droplet velocity, number of droplets and heat transfer coefficient have been analysed at different input parameters and the computed trends have been verified and validated. CFD modelling of spray indicates that it is possible to produce aerosol medium with high heat dissipation ability at moderately high air pressure and low flow rate. It also shows that any increase in atomising air pressure favourably leads to notable increase in wetting area and also results in substantial enhancement in heat dissipation ability. Reduction of residual stress is thus remarkably good. On the other hand, grinding fluid flow rate, if increased, offers significantly better lubricity and reduces the grinding force which also reduces tensile residual stress. Short spell grinding test results are found to be in good agreement with CFD results.     

Effect of grinding-induced cyclic heating on the hardened layer generation in the plunge grinding of a cylindrical component

This paper discusses the effects of the grinding-induced cyclic heating on the properties of the hardened layer in a plunge cylindrical grinding process on the high strength steel EN26. It was found that a multi-pass grinding brings about a uniform and continuous hardened layer along the circumference of the cylindrical workpiece. An increase of the number of grinding passes, leads to a thicker layer of hardening, a larger compressive residual stress and a deeper plastic deformation zone. Within the plastic deformation zone, the martensitic grains are refined by the thermo-mechanical loading, giving rise to a hardness of 12.5% higher than that from a conventional martensitic transformation. The coupled effects of heat accumulation and wheel wear in the multi-pass grinding are the main causes for the thickening of the hardened layer. A too small infeed per workpiece revolution would result in insufficient grinding heat, and in turn, bring about an undesirable tempered hardened layer and a reduction of its hardness.     

Micro-Analysis of the Contact Zone of Tribologically Loaded Second-Phase Reinforced Sol-Gel-Abrasives

Abrasives manufactured via the Sol-Gel route have increased the grinding efficiency of conventional abrasive grinding tools to a remarkable degree in the past ten years. Little is known, however, about detailed wear mechanisms of the abrasive on a nanometer scale. Sliding tests on a pin-on-disk tribometer and single grit scratching tests have therefore been performed in order to identify the wear mechanisms of these innovative materials. TEM-analysis has revealed that severe plastic deformation combined with both crack bridging and crack deflecting effects in the second phase characterise the abrasive rim zone. The surface of the abrasive is covered with an oxide debris layer which substantially improves the tribological behaviour.     

陶瓷减水剂、助磨剂、增强剂的发展现状、趋势及展望

阐述了陶瓷行业所用添加剂的分类，以及目前国际上主要生产陶瓷添加剂的厂家及主要产品，详细介绍了陶瓷坯体减水剂、助磨剂、增强剂的种类、应用、性能特点和它们与陶瓷材料的作用机理，并对陶瓷添加剂的发展前景进行了展望。     

Effects of the cryogenic cooling on the fatigue strength of the AISI 304 stainless steel ground components

For environmental considerations, the substitution of the conventionally used oil-based grinding fluids has nowadays become strongly recommended. Although several alternatives have been proposed, cryogenic cooling by liquid nitrogen is the non-polluting coolant that has been given relatively more attention because of its very low temperature. In this investigation, in order to contribute to developing this promising cooling mode, its beneficial effects on the ground surface integrity of the AISI 304 stainless steel and their consequences on the fatigue lifetime are explored. Results of this investigation show that grinding under cryogenic cooling mode generates surfaces with lower roughness, less defects, higher work hardening and less tensile residual stresses than those obtained on surfaces ground under oil-based grinding fluid. These surface enhancements result into substantial improvements in the fatigue behaviour of components ground under this cooling mode. An increasing rate of almost 15% of the endurance limit at 2 × 10⁶ cycles could be realized. SEM analyses of the fatigue fracture surfaces have shown that the fatigue cracks observed on the specimens ground under cryogenic cooling are shorter (i.e., 30-50 μm) than those generated under oil-based cooling mode (i.e., 150-200 μm). The realized improvements in the surface integrity and in the fatigue behaviour are thought to be related to the reduction of the grinding zone temperature observed under cryogenic cooling, as no significant differences between the grinding force components for both cooling modes have been observed.     

The optimal diamond wheels for grinding diamond tools

Grinding is the most suitable process for manufacturing good quality diamond tools. In this paper, diamond wheels have been studied. From the grinding of polycrystalline diamond (PCD) insets, the effects of certain factors such as the bonding material, the grit size and structure of a diamond wheel have been investigated. It is concluded that vitrified bond diamond wheels are the most suitable for grinding PCDs and the recommended grit size is mesh number 1000, which can get a good surface quality within an appropriate time. The wheel structure is another important factor. Rougher wheels (mesh #800, #1000) with the softer grade scale P yield a higher material removal rate (MRR) than scale Q. However, a finer wheel (mesh #1200) needs a tougher structure to promote its grinding ability and to have a higher MRR.     

水泥厂低投入高回报的技改途径

俄罗斯的一些水泥厂以最少的投入进行技改,旨在提高其生产效率。借助现代选粉技术改造水泥粉 磨系统,并给现有的篦式冷却机装备静止的入口段,可以低的投资,快速获取投资回报。     

一种微粉碎新设备——离心碎磨一体机

介绍一种离心碎磨一体机的工作原理、构造和特点 ,分析了碎磨机理及应用前景     

磷酸镁水泥制备试验研究

基于水工建筑物的应急抢险与快速修补加固处理的需要,运用常规的水泥凝结时间、强度等基本性能试验,研究各材料组成对磷酸镁水泥性能的影响,确定磷酸镁水泥配方,并对不同粒径砂土的磷酸镁水泥砂浆水胶比、养护条件、强度等进行了试验研究。结果表明,硼砂是磷酸镁水泥的有效缓凝剂;氧化镁细度对水泥性能有明显影响,氧化镁越细水泥早期强度越高,但细度过细凝结时间将难以满足施工要求;磷酸镁水泥配方为:P/M值1∶3,硼砂掺量10%,氧化镁细度宜为195 m~2/kg左右;磷酸镁水泥砂浆抗压强度与胶水比具有线性相关性,与龄期呈对数关系;水中养护与标准养护相比,抗压强度降低约6%～27%,磷酸盐水泥在长期水下环境中的适用性需论证。研究成果可为水工建筑物的应急抢险与快速修补加固处理提供参考和依据。