Evaluating lubricants in sheet metal forming

The sheet metal forming process basically involves the shaping of sheet metal of various thickness and material properties into the desired contours. This metal forming process has been extensively used by the automotive industry to manufacture both car panels and parts. Over the years numerous investigations have been conducted on various aspects of the manufacturing process with varied success. In recent years the requirements on the sheet metal forming industry have headed towards improved stability in the forming process while lowering environmental burdens. Therefore the overall aim of this research was to identify a technique for developing lubricant formulations that are insensitive to the sheet metal forming process. Due to the expense of running experiments on production presses and to improve time efficiency of the process the evaluation procedure was required to be performed in a laboratory. Preliminary investigations in the friction/lubricant system identified several laboratory tests capable of measuring lubricant performance and their interaction with process variables. However, little was found on the correlation between laboratory tests and production performance of lubricants. Therefore the focus of the research switched to identifying links between the performance of lubricants in a production environment and laboratory tests. To reduce the influence of external parameters all significant process variables were identified and included in the correlation study to ensure that lubricant formulations could be desensitised to all significant variables. The significant process variables were found to be sensitive to die position, for instance: contact pressure, blank coating of the strips and surface roughness of the dies were found significant for the flat areas of the die while no variables affected friction when polished drawbeads were used. The next phase was to identify the interaction between the significant variables and the main lubricant ingredient groups. Only the fatty material ingredient group (responsible for the formation of boundary lubricant regimes) was found to significantly influence friction with no interaction between the ingredient groups. The influence of varying this ingredient group was then investigated in a production part and compared to laboratory results. The correlation between production performance and laboratory tests was found to be test dependant. With both the Flat Face Friction test and the Drawbead Simulator unaffected by changes in the lubricant formulation, while the Flat Bottom Cup test showing similar results as the production trial. It is believed that the lack of correlation between the friction tests and the production performance of the lubricant is due to the absence of bulk plastic deformation of the strip. For this reason the Ohio State University (OSU) friction test was incorporated in the lubricant evaluation procedure along with a Flat Bottom Cup test. Finally, it is strongly believed that if the lubricant evaluation procedure highlighted in this research is followed then lubricant formulations can be developed confidently in the laboratory.

Creating the political will necessary for achieving multilateral disarmament : the need for a peace-industrial complex

This dissertation deals with the failure to end the central arms race and provides some alternative proposals. Chapters 1 and 2 look at the failure of governmental disarmament negotiations and the ineffectiveness of the non-governmental peace movement. Chapter 3 outlines the author's recommended comprehensive strategy for ending the arms race? both the need for the US to make a dramatic unilateral initiative to break the deadlock (Super GRIT) and a detailed disarmament treaty. The main problem, as argued by the author, is more one of political will and so it is necessary to find a way of creating the political will to stimulate the US to make that dramatic unilateral initiative. He calls for the creation of a Peace-Industrial Complex. The intellectual arguments for the potential basis of such a complex are to be found in the research done by the United Nations; this is examined throughout Part II (Chapters 4-7). Unfortunately very little attention has been paid by governments to this work. Part III (Chapters 8 and 9) deals in more detail with the recommended Peace-Industrial Complex. Chapter 8 looks at its possible creation and method of work. Chapter 9 suggests that the proposed complex creates a transcending vision: from ‘uclear winter’to ‘nuclear spring’.

Extending robust industrial optimisation using simulation and reinforcement learning

Traditional optimisation methods are incapable of capturing the complexity of today's dynamic manufacturing systems. A new methodology, integrating simulation models and intelligent learning agents, was successfully applied to identify solutions to a fundamental scheduling problem. The robustness of this approach was then demonstrated through a series of real-world industrial applications.

Key success factors in real-time industrial system assurance

The thesis analyses the issues of implementing real-time software systems in industrial applications. The benefit is the development of the Integrated Mega Project Development Model, to improve the effectiveness of planning and timely delivery of software, the quality of the delivered software and reducing problems associated with integrating software systems.

Improved synthesis of commercially valuable opiates : development of reactions for industrial applications

Describes the synthesis of thebaine and noroxymorphone - key intermediates in the synthesis of opiate drugs. The design and optimisation of these synthetic pathways were developed keeping in mind the concerns of industry.

Industrial and economic development : a holistic study of Brunei Darussalam

The primary objective of this research is to provide a framework for industrial and economic development with respect to Brunei Darussalam. The study is both novel and unique as it is potentially the most comprehensive holistic study performed to date with respect to industrial and economic development in Brunei.

Evaluation of cold forming lubricants for fastener manufacturing

Investigates the significance and interactive effects of lubricant type, workpiece surface texture and deformation rate under bulk metal, deformation conditions. A novel test rig was developed in conjunction with statistical test techniques. The result of this work identified a cold forming lubrication system with potential economic and environmental advantages over traditional lubrication systems.

Phosphonium ionic liquids as lubricants for aluminium-steel

The performance of a series of novel room temperature ionic liquids (ILs) based on the trihexyl(tetradecyl)phosphoniumcation (P66614 +) and a number of novel anions have been studied in pin-on-disk tests using a 100Cr6 steel ball on AA2024 aluminium disks.

The anions coupled to the (P66614 +) cation include diphenyl phosphate (DPP-), dibutyl phosphate (DBP-), bis (2,4,4-trimethyl pentyl) phosphinate (M3PPh-) and bis(2-ethyl hexyl) phosphate (BEH-).

More traditional anions such as bis(trifluoromethanesulfonyl) amide (NTf2 -) and bromide (Br-) were also investigated. Experiments were conducted at various loads to assess the IL film forming abilities.

The results suggest that the structure of the anion is important in forming a surface film that reduces the friction and wear of the aluminium disk. At 30N five of the six ILs tested showed a 30-90% reduction in wear, as determined from wear scar depth measurements, compared to fully formulated diesel oil.

The IL lubricant with a diphenyl phosphate anion achieved the lowest wear coefficient, showing a better performance than a typical fluorine-containing IL anion, NTf2.

To further investigate wear mechanisms and surface interactions the wear scars were analysed using a scanning electron microscope (SEM) and energy dispersive spectroscopy (EDS).

Transition in wear performance for ionic liquid lubricants under increasing load

The effect of ionic liquid (IL) lubrication for aluminium/steel systems is highly dependant on the applied load and the IL structure. This study illustrates that a change in anion of an IL lubricant results in different physicochemical properties that will alter its performance at a given load. As the load is increased there is a shift in lubricant performance and mechanism of the IL. Up to a load of 30 N the lowest wear coefficient was achieved by a phosphonium diphenylphosphate IL, whilst above 30 N a phosphonium bis(trifluoromethanesulfonyl)amide IL was able to form a more tenacious tribolayer that resulted in the lowest wear.