Advanced Materials Research Vol. 628

Abstract: In this paper, a layout is designed for reclaimed rubber factory by applying systematic layout planning (SLP) method. Considering the enterprise current situation and future development plan, the relation graph for all workshops in the company is obtained by analyzing material and non- material flows, and two feasible layout plans are put forward. Applying the comparative law of equivalent flow capacity, these two plans are compared, and then the final objective and optimal design is obtained. With this layout redesign, the logistics operational efficiency is improved, and the production system is optimized.

Abstract: Prototype observation and finite element analysis were carried out on a weld seam between a spiral case and a penstock of #6 generator in a certain power plant. According to the observation data and finite element calculated results, deformation and stress were analyzed for the weld seam in continuous operating stage (power generation, EL. 206.00). The results show that in the normal operation power generation stage, the strengths of the penstock, the spiral case and the weld seam are all satisfied; Even if the inlet water level reaches to EL. 275.00, the three parts are all safe (when the residual stress isn’t considered, the stress is far lower than the strength allowed values). However, the stress at point E is obviously higher, it is necessary to make further testing inspection. Finally the following suggestions are given: (1) the strain gauges should be arranged both circumferentially and axially, this is because the circumferential stress of weld seam is greater than axial stress; (2) the stiffener rings should be moved left by 50mm, thus the axial stress can be minimized and the circumferential stress can also be reduced.

Abstract: In this paper, metal stamping deep drawing forming process was simulated by Abaqus software. first of all, metal deep drawing forming for finite element modeling and analysis. Then the simulation results of drawing parts metal forming were analyzed. Include the analysis of stress-strain changes over time and the most serious regional. To determine the position easy to crack in the process of metal drawing parts stamping. Finally, by stamping test to verify the position of the cracks by punching test whether compliance with the simulation results. Verify the accuracy of the Abaqus software in the process of stamping simulation. Verify the accuracy of the Abaqus software simulation in metal forming processes.

Abstract: Machining processes, such as milling, are considered to be too complex to be modeled accurately by using analytical or even numeric means due to involvement of various control parameters, some of them highly vague and imprecise. Such situation calls for application of nonconventional methods for modeling the responses of interest with acceptable degree of accuracy. In this work, a computational intelligence tool, possessing quick learning ability, has been used for modeling and predicting tool’s flank wear and workpiece surface roughness in milling of cold work tool steel. Six numeric and two categorical input parameters were used in the artificial neural network model. 116 data sets were used for training the network, while 13 were used for testing. Both the responses were modeled with acceptable degree of accuracy.

Abstract: Sacrificial anode cathodic protection is one of the most widely used methods in protecting buried oil pipe lines against the corrosion damages. In the present work, a series of Aluminum alloys have been prepared as sacrificial anodes candidates to be used in the protection of the oil pipelines that pass through the Al-Hilla region. These prepared alloys were microstructurally and electrochemically characterized to evaluate their performance as Al-sacrificial anodes for cathodic protection of oil pipes The relationships between the protection potential with time, sacrificial anode life, discharge currents, and capacity of sacrificial anodes were found, taking into consideration the distance between sacrificial anode and protected steel sample. According to the results obtained, the best selection of sacrificial anodes was (Al-4% Zn-0.5% Sn) alloy at 30cm in Al-Hilla region.

Abstract: The orthogonal experiment is processed for high-speed milling superalloy GH4169 with TiAlN coated carbide inserts. The surface roughness prediction model based on cutting parameters is established by using the least-squares regression method. And the effect of cutting parameters on surface roughness is studied. According to the prediction model of surface roughness, a model of cutting parameters optimization by using genetic algorithm based on annealing penalty function is established for maximum material removal rate under specified surface roughness values. Obtain the optimal parameter combination when the surface roughness Ra≤0.2µm, and the experimental validation is done. These results provide the basis for improving processing efficiency of processing GH4169 and choosing parameters under specified constraint conditions.

Abstract: The paper presents the result of investigation on aluminum-silicon (LM6) alloy cast using pressurized lost foam casting process. The study investigated the effect of pressure and sand size on porosity of the casting produced. Air pressure of 1, 2, 3 and 4 bars was applied on the solidifying alloy poured in mould of sand sizes 16-30, 40-60, 60-100 (AFS). The porosities of casting were measured using optical microscope which was equipped with image analyzer. For porosity of castings, all surfaces of solidified castings were captured by digital camera for better observation. The results show that applying pressure during solidification of the LM6 alloy has significant influence on casting porosity of the alloy. By increasing the applied pressure, the porosity percentage based on gas porosity decreased when pressure was applied. Consequently, the removal rate of gas porosity improved by increasing the sand size to finer size 60-100 (AFS), so there is less gas porosity in samples. Besides, rising air pressure lead to fulfilling of molten which improves the casting porosity.

Abstract: Structural steel has been used since the early 1970’s in Korea as primary structural members such as columns, beams, and trusses. The materials have much higher strength such as fast construction, high load bearing capacity, high construction quality but those have a fatal weakness as well. Load-bearing capacity is going down when the structural members are contained in fire condition. Therefore, to protect the structural members made of steels from the heat energy the fire resistance performance required. Generally, the fire resistance performance have evaluated from the exact fire tests in fire furnaces. But the evaluation method takes much more time and higher expenses so, the engineering method requires. The engineering method not only adopts a science but also an engineering experience. In this paper, to make various data-bases for evaluation of structural members such as columns(H-section, RHS), beams, loaded fire tests were conducted and derived not only each limiting temperature but also fire resistance respectively.

Abstract: Magnetorheological Finishing, MRF can achieve deterministic results on different surface shapes such as flat surfaces, spherical surfaces and aspheric surfaces. MRF can also overcome many drawbacks of the conventional polishing process. The schedule uncertainties driven by edge roll and edge control are virtually eliminated with the MRF process. This paper presents a polishing wheel that combines rotation motion with revolution motion while renewing the MR fluid. Stable removal characteristic can be obtained by using the composite-rotation wheel. This paper also presents some recent results of the deterministic finishing typified by the tool and its MR fluid circulation system. An example of finishing a square optical workpiece with spherical surface will be reviewed.

Abstract: This paper deals with the new numerical methodology for prediction and optimization distortion of large welded structures. The methodology is presented on the example of fusion vacuum vessel of ITER which will be manufactured by welding. All necessary steps of methodology have been verified and now the methodology is ready for practical application. Application of our methodology leads to improve of knowledge about complex behavior and save time and budget.