Recent development in the mechanics of superplasticity and its applications

This paper reviews the recent developments in the mechanics of superplasticity and its applications in industrial practice. After introducing the phenomena of superplasticity, the basic experiments for determining material deformation behavior and related parameters, and constructing superplastic constitutive equations, are reviewed. Finite element related formulations and techniques for simulating superplastic forming are discussed, together with some practical applications. (C) 2004 Elsevier B.V. All rights reserved.

A preform design method for sheet superplastic bulging with finite element modeling

Superplastic bulging is the most successful application of superplastic forming (SPF) in industry, but the non-uniform wall thickness distribution of parts formed by it is a common technical problem yet to be overcome. Based on a rigid-viscoplastic finite element program developed by the authors, for simulation of the sheet superplastic forming process combined with the prediction of microstructure variations (such as grain growth and cavity growth), a simple and efficient preform design method is proposed and applied to the design of preform mould for manufacturing parts with uniform wall thickness. Examples of formed parts are presented here to demonstrate that the technology can be used to improve the uniformity of wall thickness to meet practical requirements. (C) 2004 Elsevier B.V. All rights reserved.

The influence of pressure during solidification of high pressure die cast aluminium telecommunications components

The effects of process variables on the quality of high-pressure die cast components was determined with the aid of in-cavity pressure sensors. In particular, the effects of set intensification pressure, delay time, and casting velocity have been investigated. The in-cavity pressure sensor has been used to determine how conditions within the die-cavity are related to the process parameters regulated by the die casting machine, and in turn the effect of variations in these parameters on the integrity of the final part. Porosity was found to decrease with increasing intensification pressure and increase with increasing casting velocity. The delay time before the application of the intensification pressure was not observed to have a significant effect on porosity levels. (c) 2006 Elsevier B.V. All rights reserved.

Entropy generation for microscale forced convection: effects of different thermal boundary conditions, velocity slip, temperature jump, viscous dissipation, and duct geometry

This work presents closed form solutions for fully developed temperature distribution and entropy generation due to forced convection in microelectromechanical systems (MEMS) in the Slip-flow regime, for which the Knudsen number lies within the range 0.001

Warranty cost analysis for second-hand products

For second-hand products sold with warranty, the expected warranty cost for an item to the manufacturer, depends on (i) the age and/or usage as well as the maintenance history for the item and (ii) the terms of the warranty policy. The paper develops probabilistic models to compute the expected warranty cost to the manufacturer when the items are sold with free replacement or pro rata warranties. (C) 2000 Elsevier Science Ltd. All rights reserved.

Modelling of froth transportation in industrial flotation cells: Part I. Development of froth transportation models for attached particles

Modelling of froth transportation, as part of modelling of froth recovery, provides a scale-up procedure for flotation cell design. It can also assist in improving control of flotation operation. Mathematical models of froth velocity on the surface and froth residence time distribution in a cylindrical tank flotation cell are proposed, based on mass balance principle of the air entering the froth. The models take into account factors such as cell size, concentrate launder configuration, use of a froth crowder, cell operating conditions including froth height and air rate, and bubble bursting on the surface. (C) 2004 Elsevier Ltd. All rights reserved.

Bubble load measurement in the pulp zone of industrial flotation machines - a new device for determining the froth recovery of attached particles

A new device has been developed to directly measure the bubble loading of particle-bubble aggregates in industrial flotation machines, both mechanical flotation cells as well as flotation column cells. The bubble loading of aggregates allows for in-depth analysis of the operating performance of a flotation machine in terms of both pulp/collection zone and froth zone performance. This paper presents the methodology along with an example showing the excellent reproducibility of the device and an analysis of different operating conditions of the device itself. (C) 2004 Elsevier B.V All rights reserved.

SubCM: A tool for improved visibility of software change in an industrial setting

Software Configuration Management is the discipline of managing large collections of software development artefacts from which software products are built. Software configuration management tools typically deal with artefacts at fine levels of granularity - such as individual source code files - and assist with coordination of changes to such artefacts. This paper describes a lightweight tool, designed to be used on top of a traditional file-based configuration management system. The add-on tool support enables users to flexibly define new hierarchical views of product structure, independent of the underlying artefact-repository structure. The tool extracts configuration and change data with respect to the user-defined hierarchy, leading to improved visibility of how individual subsystems have changed. The approach yields a range of new capabilities for build managers, and verification and validation teams. The paper includes a description of our experience using the tool in an organization that builds large embedded software systems.

Modelling of entrainment in industrial flotation cells: the effect of solids suspension

Solids concentration and particle size distribution gradually change in the vertical dimension of industrial flotation cells, subject primarily to the flotation cell size and design and the cell operating conditions. As entrainment is a two-step process and involves only the suspended solids in the top pulp region near the pulp-froth interface, the solids suspension characteristics have a significant impact on the overall entrainment. In this paper, a classification function is proposed to describe the state of solids suspension in flotation cells, similar to the definition of degree of entrainment for classification in the froth phase found in the literature. A mathematical model for solids suspension is also developed, in which the classification function is expressed as an exponential function of the particle size. Experimental data collected from three different Outokumpu tank flotation cells in three different concentrators are well fitted by the proposed exponential model. Under the prevailing experimental conditions, it was found that the solids content in the top region was relatively independent of cell operating conditions such as froth height and air rate but dependent on the cell size. Moreover, the results obtained from the total solids tend to be similar to those from a particular gangue mineral and hence may be applied to all minerals in entrainment calculation. (C) 2004 Elsevier Ltd. All rights reserved.

Gas dispersion measurements in industrial flotation cells

For nearly 100 years, the flotation plant metallurgist has often wondered what is happening 'beneath the froth'. To assist in unravelling this mystery, new technology has been developed as part of the Australian Mineral Industries Research Association (AMIRA) P9 project, to measure gas dispersion characteristics (such as gas hold-up, superficial gas velocity and bubble size) in industrial flotation cells. These measurements have been conducted in a large number of cells of different types and sizes by researchers from the Julius Kruttschnitt Mineral Research Centre (JKMRC) and JKTech. A large database has been developed and the contents of this database are described in this paper. Typical cell characterization measurements show a wide spread in values, even in the same cell types and sizes performing similar duties. In conventional flotation cells, the typical gas hold-up values range from 3% to 20%, bubble sizes range between I and 2 mm, and superficial gas velocity ranges from 1 to 2.5 cm/s. The ranges of cell characterization measurements given in this paper will enable plant personnel to compare their operation to other similar types of operations from around Australia and the rest of the world, giving opportunities for further improvement to flotation plant operations. (C) 2005 Elsevier Ltd. All rights reserved.

Modelling of entrainment in industrial flotation cells: Water recovery and degree of entrainment

Entrainment in flotation can be considered as a two-step process, including the transfer of the suspended solids in the top of the pulp region just below the pulp-froth interface to the froth phase and the transfer of the entrained particles in the froth phase to the concentrate. Both steps have a strong classification characteristic. The degree of entrainment describes the classification effect of the drainage process in the froth phase. This paper briefly reviews two existing models of degree of entrainment. Experimental data were collected from an Outokumpu 3 m(3) tank cell in the Xstrata Mt. Isa Mines copper concentrator. The data are fitted to the models and the effect of cell operating conditions including air rate and froth height on the degree of entrainment is examined on a size-by-size basis. It is found that there is a strong correlation between the entrainment and the water recovery, which is close to lineal. for the fines. The degree of entrainment decreases with increase in particle size. Within the normal range of cell operating conditions, few particles coarser than 50 mu m are recovered by entrainment. In general, the degree of entrainment increases with increase in the ail rate and decreases with increase in the froth height. Air rate and froth height strongly interact with each other and affect the entrainment process mainly via changes in the froth retention time, the froth structure and froth properties. As a result, other mechanisms such as entrapment may become important in recovering the coarse entrained particles. (c) 2005 Elsevier Ltd. All rights reserved.

Particle number emissions and source signatures of an industrial facility

The work presented was conducted within the scope of a larger study investigating impacts of the Stuart Oil Shale project, a facility operating to the north of the industrial city of Gladstone, Australia. The aims of the investigations were threefold: (a) the identification of the plant signatures in terms of particle size distributions in the submicrometer range (13-830 nm) through stack measurements, (b) exploring the applicability of these signatures in tracing the source contributions at locations of interest, at a distance from the plant, and (c) assessing the contribution of the plant to the total particle number concentration at locations of interest. The stack measurements conducted for three different conditions of plant operation showed that the particle size distributions were bimodal with average modal count median diameters (CMDs) of 24 (SD 4) and 52 (SD 9) nm. The average of all the particle size distributions recorded within the plant sector at a site located 4.5 km from the plant, over the sampling period when the plant was operating, also showed a bimodal distribution. The modal CMDs in this case were 27 and 50 nm, similar to those at the stack. This bimodal size distribution is distinct from the size distribution of the most common ambient anthropogenic emission source, which is vehicle emissions, and can be considered as a signature of this source. The average contribution of the plant (for plant sector winds) was estimated to be (10.0 +/- 3.8) x 10(2) particles cm(-3) and constituted approximately a 50% increase over the local particle ambient concentration for plant sector winds. This increase in particle number concentration compared to the local background concentration, while high compared to the clean environment concentration, is not significant when compared to concentrations generally encountered in the urban environment of Brisbane.