Development of the sheared edge in the trimming of steel and light metal sheet, part 2 - mechanisms and modelling

The shearing behavior of a drawing-steel and aluminum alloy were investigated using hardness contours of partially deformed samples and a finite element model of the trimming process. Results showed that the stress and strain distributions within the work-piece were more strongly dependent on the punch penetration than the material properties of the work-piece. Differences in the final fracture surface profile and burr formation of the drawing-steel and aluminum alloy were a consequence of the shape of the stress and strain distribution when the crack in the sample became unstable, not when it was initiated. Results and existing literature suggest that a correlation may exist between the strain-rate sensitivity of the work-piece material and the burr mechanism and fracture surface profile of the trimmed part.

Estimating quality costs in an automotive stamping plant through the use of simulation

The pressures of modern manufacturing require that the quality-cost benefits are determined when evaluating new procedures or alternative operating policies. Traditionally, cost reports and other quality metrics have been used for this purpose. However, the interactions between the main quality cost drivers cannot be understood at the superficial level and the effect that a new process or an alternative operating policy may have on quality costs is difficult to determine. An alternative to the traditional costing methods is simulation. The current work uses simulation to evaluate quality costs in an automotive stamping plant where the quality control is determined by operator inspection of their own work. Self-inspection quality control provides instantaneous feedback of quality problems, allowing for quick rectification. However, the difficult nature of surface finish inspection of automotive panels can create inspection and control errors. A simulation model was developed to investigate the cost effects of inspection and control errors and it was found that inspection error had a significant effect in increasing total quality cost, with the magnitude of this increase dependent on the level of control. Further, the simulation found that the lowest cost quality control policy was that which allowed a number of defective panels to accumulate before resetting the press-line.

Development of the sheared edge in the trimming of steel and light metal sheet, part 1 - experimental observations

Trimming experiments were conducted on sheet metals including two drawing steels, an aluminum alloy and a magnesium alloy, using a specially designed die in a mechanical press. The punch-die clearance was varied and data obtained on the rollover and burr height as a function of the clearance. Samples were also partially trimmed to examine crack initiation, the generation of the fracture surface profile and mechanism of burr formation. The results showed that while the burr height and rollover depth generally increased with increasing clearance for all examined materials, there were differences in the fracture surface profile shape, the burr shape, and the mechanism of burr formation, between the two steels and the two light alloys. The major cause of these differences appeared to be the rate of crack propagation through the sheet material.

Assessment methods in social work education: a review of the literature

Student assessment is an important component of social work education, and consumes considerable effort on behalf of both students and staff members. Social work educators in higher education face the challenge of constructing assessment methods, which encourage the development of reflective and critical learning, as well as enabling students to demonstrate acquisition of required knowledge and/or skills. While there is now a substantial literature on field education, the assessment of classroom-based units has warranted less attention. This paper examines the range of assessment methods reported in the social work education literature, the evidence which supports the use of these methods and issues associated with the identified assessment methods.

Validation of the use of Australian input-output data for building embodied energy simulation

Traditional!y, the simulation of buildings has focused 011 operational energy consumption in an attempt to determine the potential for energy savings. Whilst operational energy of Australian buildings accounts for around 20% of total energy consumption nationally, embodied energy represents 20 to 50 times the annual operational energy of 1110st Australian buildings. Lower values have been shown through a number of studies that have analysed the embodied energy of buildings and their products, however these have now shown to be incomplete in system boundary. Many of these studies have used traditional embodied energy analysis methods, such as process analysis and input-output analysis, Hybrid embodied energy analysis methods have been developed, but these need to be compared and validated. This paper reports on preliminary work on this topic. The findings so far suggest that current best-practice methods are sufficiently accurate for most typical applications, but this is heavily dependant upon data quality and availability.

Application of the strain localization CAFE model to investigate extrusion with various die shapes

Multi scale CAFE model for the prediction of initiation and propagation of the micro shear bands and shear bands in metallic materials subjected to plastic deformation is presented. The CAFE approach is the combination of the Cellular Automata (CA) and the Finite Element (FE) methods. The application of the developed CAFE model to analyze material flow during extrusion is the objective of the present work. The proposed CAFE approach is applied in this work to simulation of the extrusion with flat face and convex dies and to investigate differences in the material flow. The initial FE meshes with the set of the CA point are generated for the numerical tests and the results of the metal flow predicted by the CAFE method are presented in the paper.

Fuzzy concepts and formal methods

It has been recognised that formal methods are useful as a modelling tool in requirements engineering. Specification languages such as Z permit the precise and unambiguous modelling of system properties and behaviour. However some system problems, particularly those drawn from the information systems problem domain, may be difficult to model in crisp or precise terms. It may also be desirable that formal modelling should commence as early as possible, even when our understanding of parts of the problem domain is only approximate. This thesis suggests fuzzy set theory as a possible representation scheme for this imprecision or approximation. A fuzzy logic toolkit that defines the operators, measures and modifiers necessary for the manipulation of fuzzy sets and relations is developed. The toolkit contains a detailed set of laws that demonstrate the properties of the definitions when applied to partial set membership. It also provides a set of laws that establishes an isomorphism between the toolkit notation and that of conventional Z when applied to boolean sets and relations. The thesis also illustrates how the fuzzy logic toolkit can be applied in the problem domains of interest. Several examples are presented and discussed including the representation of imprecise concepts as fuzzy sets and relations, system requirements as a series of linguistically quantified propositions, the modelling of conflict and agreement in terms of fuzzy sets and the partial specification of a fuzzy expert system. The thesis concludes with a consideration of potential areas for future research arising from the work presented here.

Simulation of Mg sheet press cell materials

Major characteristics of Magnesium alloy are low density (= 1.8 g/cm³) and excellent recyclability; therefore Mg is considered as one of low environmental loading materials. The low-density materials, such as Mg, are suitable for the transportation system to reduce the emission of Co2, save energy resource and increase the safety for accidents like corrosions. In the place, cellular materials like aluminum foams are also low-density materials and can be controlled the stress-strain relation. Combination of Mg alloy and cellular materials, that is Mg cell, is one of the most excellent materials for transportation system, because of its ultra low density. safeties, and recycle ability. To make the Mg cellular materials. there are some problems to solve. One is how to make them uniformly to supply them as same perfonnance materials. One is how to make them inexpensively. Most of cellular materials are very expensive because of there are many processes or special fabrication system to make them. To solve these problems. we investigated the press cell materials. The press cell material consists sheets pressed as cell shape and wall. Therefore, it is very easy to make cellular materials and control validation of the performance of each foam materials. In this paper, we simulated compression tests of this new type of Mg alloy cellular materials under dynamic loading to investigate the relation between the compression speed and the compression behavior to show the shock absorbing capability of this new foam material. It is very important to understand their mechanical properties relatcd with cell shapes and wall to be applied widely.

Work readiness in graduate recruitment and selection : a review of current assessment methods

Graduate recruitment and selection differs from other contexts in that graduate applicants generally lack job-related experience. Recent research has highlighted that employers are placing increasing value on graduates being work ready. Work readiness is believed to be indicative of graduate potential in terms of long term job performance and career advancement. A review of the literature has found that current graduate recruitment and selection practices lack the rigour and construct validity to effectively assess work readiness. In addition, the variety of interchangeable terms and definitions articulated by employers and academics on what constitutes work readiness suggests the need to further refine this construct. This paper argues that work readiness is an important selection criterion, and should be examined systematically in the graduate assessment process, as a construct in itself. The ineffectiveness of current assessment methods in being able to measure work readiness supports the need to develop a specific measure of work readiness that will allow more effective decision practices and potentially predict long term job capacity and performance.

The effect of skin passing on the material behavior of metal strip in pure bending and tension

The metal strip used in roll forming has often been preprocessed by (tension or roller) leveling or by skin-pass rolling, and as a consequence, may contain residual stresses. These stresses are not well observed by the tensile test, but could have a significant effect on the bending and springback behavior. With the advent of improved process design techniques for roll forming, including advanced finite element techniques, the need for precise material property data has become important. The major deformation mode of roll forming is that of bending combined with unloading and reverse bending, and hence property data derived from bend tests could be more relevant than that from tensile testing.

This work presents a numerical study on the effect of skin passing on the material behavior of stainless steel strip in pure bending and tension. A two dimensional (2-D) numerical model was developed using Abaqus Explicit to analyze the affect of skin passing on the residual stress profile across a section for various working conditions. The deformed meshes and their final stress fields were then imported as pre-defined fields into Abaqus Standard, and the post-skin passing material behavior in pure bending was determined. The results show that a residual stress profile is introduced into the steel strip during skin passing, and that its shape and stress level depend on the overall thickness reduction as well as the number of rolling passes used in the skin passing process. The material behavior in bending and the amount of springback changed significantly depending on the skin pass condition.

Automotive engineering metal foam structures: fabrication, characterisation, testing and simulation

The contrubution of this thesis is to generate fundamental research and design information on the impact and bending behaviours of metal foams and foam-filled tubes

Studies on the interaction between malanin and metal ions by fluorescence spectra methods

A novel protein with anti-tumor activities named malanin was isolated and purified from an endemic plant in Yunnan and Guangxi provinces. Effects of copper ion, silver ion and calcium ion on malanin and apo-malanin fluorescence spectra were studied. The results showed that copper ion leads to obvious statistic quenching of malanin and apo-malanin fluorescence. The dissociation constant of them from malanin and apo-malanin were about 2.37×10-4 and 2.66×10-4 mol·L-1, respectively. The silver ion did not have quenching action on malanin fluorescence, but it had statistic quenching effect on apo-malanin fluorescence, and its dissociation constant was 2.37×10-4 mol·L-1. Calcium ion did not have quenching action on malanin and apo-malanin fluorescence. It plays an important role in keeping malanin natural conformation.

The impact of sleep restriction while performing simulated physical firefighting work on cortisol and heart rate responses

PURPOSE: Physical work and sleep restriction are two stressors faced by firefighters, yet the combined impact these demands have on firefighters' acute stress responses is poorly understood. The purpose of the present study was to assess the effect firefighting work and sleep restriction have on firefighters' acute cortisol and heart rate (HR) responses during a simulated 3-day and 2-night fire-ground deployment. METHODS: Firefighters completed multiple days of simulated physical work separated by either an 8-h (control condition; n = 18) or 4-h sleep opportunity (sleep restriction condition; n = 17). Salivary cortisol was sampled every 2 h, and HR was measured continuously each day. RESULTS: On day 2 and day 3 of the deployment, the sleep restriction condition exhibited a significantly higher daily area under the curve cortisol level and an elevated cortisol profile in the afternoon and evening when compared with the control condition. Firefighters' HR decreased across the simulation, but there were no significant differences found between conditions. CONCLUSION: Findings highlight the protective role an 8-h sleep opportunity between shifts of firefighting work has on preserving normal cortisol levels when compared to a 4-h sleep opportunity which resulted in elevated afternoon and evening cortisol. Given the adverse health outcomes associated with chronically high cortisol, especially later in the day, future research should examine how prolonged exposure to firefighting work (including restricted sleep) affects firefighters' cortisol levels long term. Furthermore, monitoring cortisol levels post-deployment will determine the minimum recovery time firefighters need to safely return to the fire-ground.

Comparison of different extrusion methods for compaction of powders

Densification of metallic powders by means of extrusion is regarded as a very attractive processing technique that allows obtaining a high level of relative density of the compact. However, the uniformity of the relative density depends on that of strain distribution and on the processing parameters. Several variants of extrusion can be used for compaction of metal particulates, including the conventional extrusion (CE) and equal channel angular pressing (ECAP), often referred to as equal-channel angular extrusion. Each of these processes has certain advantages and drawbacks with respect to compaction. A comparative study of these two extrusion processes influencing the relative density of compacts has been conducted by numerical simulation using commercial finite element software DEFORM2D. The results have been validated by experiments with titanium and magnesium powders and chips.