Elastic behaviour in mechanical draw presses

This thesis explores the elastic behaviour of the mechanical double action press and draw die system commonly used to draw sheet metal components in the automotive industry. High process variability in production and excessive time spent in die try-out are significant problems in automotive stamping. It has previously been suggested that the elastic behaviour of the system may contribute to these problems. However, the mechanical principles that cause the press system to affect the forming process have not been documented in detail. Due to a poor understanding of these problems in industry, the elasticity of the press and tools is currently not considered during the die design. The aim of this work was to explore the physical principles of press system elasticity and determine the extent to which it contributes to problems in try-out and production. On the basis of this analysis methods were developed for controlling or accounting for problems during the design process. The application of frictional restraining force to the edges of the blank during forming depends on the distribution and magnitude of the clamping force between the binders surfaces of the draw die. This is an important control parameter for the deep drawing process. It has been demonstrated in this work that the elasticity of the press and draw die can affect clamping force in two ways. The response of the press system, to the forces produced in the press during forming, causes the magnitude of clamping force to change during the stroke. This was demonstrated using measured data from a production press. A simple linear elastic model of the press system was developed to illustrate a definite link between the measured force variation and the elasticity of the press and tools. The simple model was extended into a finite element model of the complete press system, which was used to control a forming simulation. It was demonstrated that stiffness variation within the system could influence the final strains in a drawn part. At the conclusion of this investigation a method is proposed for assessing the sensitivity of a part to clamping force variation in the press during die design. A means of reducing variation in the press through the addition of a simple linear spring element is also discussed. The second part of the work assessed the influence of tool structure on the distribution of frictional restraining forces to the blank. A forming simulation showed that tool stiffness affects the distribution of clamping pressure between the binders. This was also shown to affect the final strains in a drawn part. However, the most significant influence on restraining force was the tendency of the blank to increase in thickness between the binders during forming. Using a finite element approximation of the try-out process it was shown that the structure of the tool would also contribute to the problems currently experienced in try-out where uneven contact pressure distributions are addressed by manually adjusting the tool surfaces. Finally a generalised approach to designing draw die structures was developed. Simple analysis methods were combined with finite element based topology optimisation techniques to develop a set of basic design guidelines. The aim of the guidelines was to produce a structure with uniform stiffness response to a pressure applied at the binder surface. The work concludes with a recommendation for introducing the methods developed in this thesis into the standard production process.

Enterprise systems for innovation in products and processes : beyond operational efficiency

It has been widely accepted now in industry and academia that Enterprise Systems (ES) can create value for adopting organizations by enabling operational efficiency. However, given the enormous investments they warrant, the potential of such systems to deliver more than improving operations is emerging as a popular area of investigation. This paper reports a research-in-progress that proposes innovation as a means of creating business value with Enterprise Systems. The primary contribution of this paper is a process model that proposes that Enterprise Systems can enable innovation - in products and processes, and supports it with empirical evidence using three case studies. The intention is to test this model further with more case studies and a survey.

Concurrent undergraduate study and industry employment - the Australian experience

Undergraduate education in Quantity Surveying (QS) and Construction Management (CM) in Australia has traditionally incorporated concurrent industry experience as an important requisite prior to graduation. This has been primarily driven by accrediting professional associations but most universities have also recognized the value of this cooperative approach to education with industry. However, in recent years many universities have become concerned about the amount of time that students are spending in industry employment to the point where, for some students, their employment takes precedence over their academic studies. Past research has shown that working long hours has a negative effect on the study patterns of undergraduate students. This paper presents the results of research undertaken to examine the amount of time that Quantity Surveying and Construction Management students actually spend engaged in paid work during semester time and the impact on their studies. The methodology for the research was based on two separate questionnaire surveys distributed to undergraduate Quantity Surveying and Construction Management students at 7 universities across Australia. The questionnaires focused on the nature and extent of their paid work while enrolled in full-time study. The results indicate that students in the early stages of their program tend to undertake casual work that is not related to their degree but move to construction industry employment in the later stages of their program. The research found that students were spending an average of 18 hours per week in industry employment with this average increasing to over 23 hours in their final year. A number of students were spending well over 30 hours per week in industry employment. The implications of the extent of this concurrent industry employment are discussed.

A novel defect detection and identification method in optical inspection

Optical inspection techniques have been widely used in industry as they are non-destructive. Since defect patterns are rooted from the manufacturing processes in semiconductor industry, efficient and effective defect detection and pattern recognition algorithms are in great demand to find out closely related causes. Modifying the manufacturing processes can eliminate defects, and thus to improve the yield. Defect patterns such as rings, semicircles, scratches, and clusters are the most common defects in the semiconductor industry. Conventional methods cannot identify two scale-variant or shift-variant or rotation-variant defect patterns, which in fact belong to the same failure causes. To address these problems, a new approach is proposed in this paper to detect these defect patterns in noisy images. First, a novel scheme is developed to simulate datasets of these 4 patterns for classifiers' training and testing. Second, for real optical images, a series of image processing operations have been applied in the detection stage of our method. In the identification stage, defects are resized and then identified by the trained support vector machine. Adaptive resonance theory network 1 is also implemented for comparisons. Classification results of both simulated data and real noisy raw data show the effectiveness of our method.

Finite element analysis of residual stresses in metallic coatings through a compound casting

Al and Mg alloys are widely used in industry as main lightweight alloys. They have excellent properties, such as low density, high ductility, and high specific strength, and so on. Generally speaking, Mg alloys are better than Al alloys. However the corrosion of Mg alloys is much more difficult to control compared Al alloys. Therefore to combine these two lightweight alloys, a composite-like structure is an ideal solution since Al alloys can be used as protective coatings for Mg alloys. Compound casting is a realistic technique to get this coating system. In the current study, we numerically study the compound casting using finite element method (FEM) to make these two alloys, a composite-like structure, satisfy requirements to resist corrosion required from industry, in which the aluminum layer is acting as a protective coating for the magnesium substrate. Several finite element models have been developed by using the birth and death element technique and we focus on compound casting-induced residual stresses in the compounded structure. The numerical results obtained from the proposed finite element models show the distribution profiles of thermal residual stresses. We found the major factors influencing the residual stresses are the temperature to pre-heating the Al substrate and the thickness of Mg deposits. © (2014) Trans Tech Publications, Switzerland.

Improving student-industry engagement through project oriented curriculum

Industry expects a creative and innovative academic practice that provides students with valuable practical knowledge focused on graduate ready skills for future careers. The learning environment in engineering is inadequate for students to become a skillful graduate. The practical role of engineering is gained through working on real world problems in an industry collaborative environment through projects. Industry academia collaboration seems to be actively increasing in the development of engineering education in various parts of the globe. The close relationship between industry and academia is a vital component of the engineering pedagogy to improve student engagement in industry through projects. By engaging students with industry, students will acquire global perspective about the core attributes expected in future engineering jobs. In today’s large-scale industrial market, companies tend to prefer graduates with design skills attained through the project approach. Thus, universities should open their doors and accept the challenges of interacting with students with industrial experiences and expectations. This paper is focused on improving student industry engagement through project/design oriented curriculum. Through quantitative and qualitative research, the paper shows the industry perspectives and students views on university and industry collaboration. The research results show that students and industry can possibly maintain their engagement by providing regular feedback, reviewing goals and objectives, improving communication, keeping focused, and sharing a similar vision.

LTE networking : extending the reach for sensors in mHealth applications

Sensor and electronic-health networks are widely utilized at home and in industry/research applications. In a local sense, a sensor-to-sensor network can have a range of a few meters to a couple of hundred meters (ZigBee Pro can extend this range up to 2000 m). With the deployment of mobile technology in the healthcare space (mobile-Health ‘m-Health’) and using cellular coverage, the range can virtually be unbounded. However, supporting bounded delay (end-to-end delay), class of service, and quality of service for critical sensor-mHealth applications may become challenging. This challenge can be alarmingly extended when thousands of users run their sensor-mHealth applications simultaneously and depend on limited coverage of the cell tower to transmit their health-related data across. In this paper we will discuss how the 3rd Generation Partnership Project–Long Term Evolution networks can address such aggregation issues, and discuss the challenges and provide recommendations.

Emerging technologies for recovery of value-added components from olive leaves and their applications in food/feed industries

Olive leaves are the most abundant agricultural waste source rich in polyphenolics. Due to the numerous health benefits associated with these compounds, the interest in recovering polyphenols from olive leaves has increased in the scientific community over the last decade. Recent studies have focused on improved extraction techniques and processing methods that are most suited for agro-biological industries involved in the development of nutraceutical and functional products. The major problems in olive leaves processing include bitter taste and the low stability of various phenolic compounds. Oleuropein and hydroxytyrosol are the most important phenolic compounds extracted from olive leaves. The present review highlights the importance of olive leaves, their composition, preparation methods, major phenolic compounds, and commercial applications. This review article focuses on integrating studies on olive leaf extract (OLE) pertinent to nutrition, health, and beauty. The different board categories of delivery systems available for the encapsulation of OLE are given. These novel delivery systems could improve fortification, supplementation, and dietary diversification in food and pharmaceutical products.

Global review of permian Tyloplecta muir-wood and cooper, 1960 (Brachiopoda): morphology, palaeobiogeographical and palaeogeographical implications

A global review of the stratigraphical and geographical distribution of Tyloplecta reveals that the genus ranges in age from Kungurian to Changhsingian (Middle to Late Permian). Tyloplecta first evolved in South China in the Kungurian (late Early Permian). The genus went through its first diversification in the Guadalupian, suffered a major extinction at the end of the Guadalupian, and re-diversified in the Wuchiapingian. T. yangtzeensis persisted into the Changhsingian as the only survivor of the genus involved in the end-Permian mass extinction. Palaeogeographically, South China is not only the centre of origin for the genus but also an area of diversification and evolution. In addition to South China, Tyloplecta has also been recorded from the Far East Russia, Japan, central Thailand, Laos, Cambodia, Qiangtang Terrane of Tibet, Salt Range, Iran, Armenia, Hungary, Yugoslavia, and Slovenia. This geographic spread suggests that Tyloplecta was primarily restricted to the Palaeotethys and is indicative of warm-water palaeoequatorial conditions. Its presence in some of the northeast Asian terranes (e.g., parts of Japan and Far East Russia) and in the Salt Range (Pakistan) and central and north Iran (part of the Cimmerian microcontinents) demonstrate that the genus invaded the middle palaeolatitudinal regions in both hemispheres during the late Middle Permian in response to increased shallow marine biotic communications between Cathaysia in the eastern Palaeotethys and southern Angaraland, and between Cathaysia and Peri-Gondwanaland. The invasion of Tyloplecta (and some other taxa) into the southern shore waters of Angaraland may be explained by assuming ocean surface current connections and close palaeogeographical proximities between the South China, Sino-Korea and Bureya blocks. In comparison, the invasion of Tyloplecta into the Peri-Gondwanaland region is more likely a result of reduced palaeogeographical distance between South China and Peri-Gondwanaland and the appearance of the Cimmerian microcontinents as migratory stepping stones.

The effects of technical and social conditions on workplace trust

This paper investigates the extent to which the technical and social contexts of organizations independently affect levels of workplace trust. We argue that, in an organizational context, trust is not just a relationship between an individual subject (the truster) and an object (the trustee) but is subject to effects from the conditions of the work relationship itself. We describe the organizational context as comprising both a technical system of production (where work gets done through the specification of tasks) and a social system of work (where problems of effort, compliance, conformity and motivation are managed). We analyse the relationship between trust and these two aspects of workplace context (technical and social systems). We also operationalize this in terms of differences between industries,  occupational composition and human resource management practices. The model is tested using data drawn from the 1995 Australian Workplace Industrial Relations Survey. The results confirm that differences in industry, occupational composition and HRM practices all impact on levels of workplace trust. We review these results in terms of their implications for future research into the problem of analysing variation in trust at both the workplace and individual levels.

Simulation optimization for process scheduling through simulated annealing

This paper presents a simulation optimization of a real scheduling problem in industry, simulated annealing is introduced for this purpose.  Investigation is performed into the practicality of using simulated annealing to produce high quality schedules.  Results on the solution quality and computational effort show the inherent properties of the simulated annealing.  It is shown that when using this method, high quality schedules can be produced within reasonable time contraints.

Intervention programmes to recruit female computing students : why do the programme champions do it?

This paper looks at intervention programmes to improve the representation of female students in computing education and the computer industry, A multiple case study methodology was used to look at major intervention programmes conducted in Australia. One aspect of the research focused on the programme champions; those women from the computing industry, those working within government organisations and those in academia who instigated the programmes. The success of these intervention programmes appears to have been highly dependent upon not only the design of the programme but on the involvement of these strong individuals who were passionate and worked tirelessly to ensure the programme's success. This paper provides an opportunity for the voices of these women to be heard. It describes the champions' own initial involvement with computing which frequently motivated and inspired them to conduct such programmes. The research found that when these types of intervention programmes were conducted by academic staff the work was undervalued compared to when the activities were conducted by staff in industry or in government. The academic environment was often not supportive of academics who conducted intervention programmes for female students.

Modeling and simulation for large scale production systems

Computer modeling and simulation provide a foundation upon which industrial processes and systems can be transformed and innovation dramatically accelerated. Computer modeling and simulation is also an indispensable tool of the information age, used extensively in design, analysis, operations, decision-making, optimization, and education and training. Manufacturing, production and design relies upon simulation to develop efficient production systems and factories that produce quality products. Simulation in industry has yet to meet its full potential. The development of models is very time consuming, particularly for geometries of complex engineering systems such as manufacturing plants, automobiles, aircraft and ships. Computer simulation allows scientists and engineers to understand and predict three-dimensional and time-dependent phenomena in science and engineering discipline. This talk will focus on challenges associated with modeling and simulation in the manufacturing sector and through a number of case studies highlight the benefits gained through the use of such technologies.

Exposure to fumes and gases during welding operations

The exposure to fumes and gases is one of the hazards associated with welding operations. Apart from research conducted on the mechanism of fume and gas formation and the relationship between fume formation rates and common welding parameters, little is known about the exposure process during welding. This research project aimed to identify the factors that influence exposure, develop an understanding of their role in the exposure process and through this understanding formulate strategies for the effective control of exposure during welding. To address these aims a literature review and an experimental program was conducted The literature review surveyed epidemiological, toxicological and exposure data. The experimental program involved three approaches, the first, an evaluation of the factors that influence exposure by assessing a metal inert gas/mild steel welding process in a workshop setting. The second approach involved the study of exposure in a controlled environment provided by a wind tunnel and simulated welding process. The final approach was to investigate workplace conditions through an assessment of exposure and control strategies in industry. The exposure to fumes and gases during welding is highly variable and frequently in excess of the health based exposure standards. Exposure is influenced by a number of a factors including the welding process, base material, arc time, electrode, arc current, arc voltage, arc length, electrode polarity, shield gas, wire-to-metal-work distance (metal inert gas), metal transfer mode, intensity of the UV radiation (ozone), the frequency of arc ignitions (ozone), thermal buoyancy generated by the arc process, ventilation (natural and mechanical), the welding environment, the position of the welder, the welders stance, helmet type, and helmet position. Exposure occurs as a result of three processes: the formation of contaminants at or around the arc region; their transport from the arc region, as influenced by the entry and thermal expansion of shield gases, the vigorous production of contaminants, thermal air currents produced by the heat of the arc process, and ventilation; and finally the entry of contaminants into the breathing zone of the welder, as influenced by the position of the welder, the welders stance, helmet type, and the helmet position. The control of exposure during welding can be achieved by several means: through the selection of welding parameters that generate low contaminant formation rates; through the limitation of arc time; and by isolating the breathing zone of the welder from the contaminant plume through the use of ventilation, welder position or the welding helmet as a physical barrier. Effective control is achieved by careful examination of the workplace, the selection of the most appropriate control option, and motivation of the workforce.

Comprehensive embodied energy analysis framework

The assessment of the direct and indirect requirements for energy is known as embodied energy analysis. For buildings, the direct energy includes that used primarily on site, while the indirect energy includes primarily the energy required for the manufacture of building materials. This thesis is concerned with the completeness and reliability of embodied energy analysis methods. Previous methods tend to address either one of these issues, but not both at the same time. Industry-based methods are incomplete. National statistical methods, while comprehensive, are a ‘black box’ and are subject to errors. A new hybrid embodied energy analysis method is derived to optimise the benefits of previous methods while minimising their flaws. In industry-based studies, known as ‘process analyses’, the energy embodied in a product is traced laboriously upstream by examining the inputs to each preceding process towards raw materials. Process analyses can be significantly incomplete, due to increasing complexity. The other major embodied energy analysis method, ‘input-output analysis’, comprises the use of national statistics. While the input-output framework is comprehensive, many inherent assumptions make the results unreliable. Hybrid analysis methods involve the combination of the two major embodied energy analysis methods discussed above, either based on process analysis or input-output analysis. The intention in both hybrid analysis methods is to reduce errors associated with the two major methods on which they are based. However, the problems inherent to each of the original methods tend to remain, to some degree, in the associated hybrid versions. Process-based hybrid analyses tend to be incomplete, due to the exclusions associated with the process analysis framework. However, input-output-based hybrid analyses tend to be unreliable because the substitution of process analysis data into the input-output framework causes unwanted indirect effects. A key deficiency in previous input-output-based hybrid analysis methods is that the input-output model is a ‘black box’, since important flows of goods and services with respect to the embodied energy of a sector cannot be readily identified. A new input-output-based hybrid analysis method was therefore developed, requiring the decomposition of the input-output model into mutually exclusive components (ie, ‘direct energy paths’). A direct energy path represents a discrete energy requirement, possibly occurring one or more transactions upstream from the process under consideration. For example, the energy required directly to manufacture the steel used in the construction of a building would represent a direct energy path of one non-energy transaction in length. A direct energy path comprises a ‘product quantity’ (for example, the total tonnes of cement used) and a ‘direct energy intensity’ (for example, the energy required directly for cement manufacture, per tonne). The input-output model was decomposed into direct energy paths for the ‘residential building construction’ sector. It was shown that 592 direct energy paths were required to describe 90% of the overall total energy intensity for ‘residential building construction’. By extracting direct energy paths using yet smaller threshold values, they were shown to be mutually exclusive. Consequently, the modification of direct energy paths using process analysis data does not cause unwanted indirect effects. A non-standard individual residential building was then selected to demonstrate the benefits of the new input-output-based hybrid analysis method in cases where the products of a sector may not be similar. Particular direct energy paths were modified with case specific process analysis data. Product quantities and direct energy intensities were derived and used to modify some of the direct energy paths. The intention of this demonstration was to determine whether 90% of the total embodied energy calculated for the building could comprise the process analysis data normally collected for the building. However, it was found that only 51% of the total comprised normally collected process analysis. The integration of process analysis data with 90% of the direct energy paths by value was unsuccessful because: • typically only one of the direct energy path components was modified using process analysis data (ie, either the product quantity or the direct energy intensity); • of the complexity of the paths derived for ‘residential building construction’; and • of the lack of reliable and consistent process analysis data from industry, for both product quantities and direct energy intensities. While the input-output model used was the best available for Australia, many errors were likely to be carried through to the direct energy paths for ‘residential building construction’. Consequently, both the value and relative importance of the direct energy paths for ‘residential building construction’ were generally found to be a poor model for the demonstration building. This was expected. Nevertheless, in the absence of better data from industry, the input-output data is likely to remain the most appropriate for completing the framework of embodied energy analyses of many types of products—even in non-standard cases. ‘Residential building construction’ was one of the 22 most complex Australian economic sectors (ie, comprising those requiring between 592 and 3215 direct energy paths to describe 90% of their total energy intensities). Consequently, for the other 87 non-energy sectors of the Australian economy, the input-output-based hybrid analysis method is likely to produce more reliable results than those calculated for the demonstration building using the direct energy paths for ‘residential building construction’. For more complex sectors than ‘residential building construction’, the new input-output-based hybrid analysis method derived here allows available process analysis data to be integrated with the input-output data in a comprehensive framework. The proportion of the result comprising the more reliable process analysis data can be calculated and used as a measure of the reliability of the result for that product or part of the product being analysed (for example, a building material or component). To ensure that future applications of the new input-output-based hybrid analysis method produce reliable results, new sources of process analysis data are required, including for such processes as services (for example, ‘banking’) and processes involving the transformation of basic materials into complex products (for example, steel and copper into an electric motor). However, even considering the limitations of the demonstration described above, the new input-output-based hybrid analysis method developed achieved the aim of the thesis: to develop a new embodied energy analysis method that allows reliable process analysis data to be integrated into the comprehensive, yet unreliable, input-output framework. Plain language summary Embodied energy analysis comprises the assessment of the direct and indirect energy requirements associated with a process. For example, the construction of a building requires the manufacture of steel structural members, and thus indirectly requires the energy used directly and indirectly in their manufacture. Embodied energy is an important measure of ecological sustainability because energy is used in virtually every human activity and many of these activities are interrelated. This thesis is concerned with the relationship between the completeness of embodied energy analysis methods and their reliability. However, previous industry-based methods, while reliable, are incomplete. Previous national statistical methods, while comprehensive, are a ‘black box’ subject to errors. A new method is derived, involving the decomposition of the comprehensive national statistical model into components that can be modified discretely using the more reliable industry data, and is demonstrated for an individual building. The demonstration failed to integrate enough industry data into the national statistical model, due to the unexpected complexity of the national statistical data and the lack of available industry data regarding energy and non-energy product requirements. These unique findings highlight the flaws in previous methods. Reliable process analysis and input-output data are required, particularly for those processes that were unable to be examined in the demonstration of the new embodied energy analysis method. This includes the energy requirements of services sectors, such as banking, and processes involving the transformation of basic materials into complex products, such as refrigerators. The application of the new method to less complex products, such as individual building materials or components, is likely to be more successful than to the residential building demonstration.