Using the solid-shell element to model the roll forming of large radii profiles

Roll forming is an incremental bending process for forming metal sheet, strip or coiled stock. Although Finite Element Analysis (FEA) is a standard tool for metal forming simulation, it is only now being increasingly used for the analysis of the roll forming process. This is because of the excessive computational time due to the long strip length and the multiple numbers of stands that have to be modelled. Typically a single solid element is used through the thickness of the sheet for roll forming simulations. Recent investigations have shown that residual stresses introduced during steel processing may affect the roll forming process and therefore need to be included in roll forming simulations. These residual stresses vary in intensity through the thickness and this cannot be accounted for by using only one solid element through the material thickness, in this work a solid-shell element with an arbitrary number of integration points has been used to simulate the roll forming process. The system modelled is that of roll forming a V-channel with dual phase DP780 sheet steel. In addition, the influence of other modelling parameters, such as friction, on CPU time is further investigated. The numerical results are compared to experimental data and a good correlation has been observed. Additionally the numerical results show that the CPU time is reduced in the model without friction and that considering friction does not have a significant effect on springback prediction in the numerical analysis of the roll forming process.

Using geometric shape variations to create an inverse model for a sheet metal process

The output of the sheet metal forming process is subject to much variation. This paper develops a method to measure shape variation in channel forming and relate this back to the corresponding process parameter levels of the manufacturing set-up to create an inverse model. The shape variation in the channels is measured using a modified form of the point distribution model (also known as the active shape model). This means that channels can be represented by a weighting vector of minimal linear dimension that contains all the shape variation information from the average formed channel.

The inverse models were created using classifiers that related the weighting vectors to the process parameter levels for the blank holder force (BHF), die radii (DR) and tool gap (TG) of the parameters. Several classifiers were tested: linear, quadratic Gaussian and artificial neural networks. The quadratic Gaussian classifiers were the most accurate and the most consistent type of classifier over all the parameters.

A shape error metric for sheet metal forming and its application to springback

There are many variations within sheet metal forming, some of which are manifest in the final geometry of the formed component. It is important that this geometric variation be quantified and measured for use in a process or quality control system. The contribution of this paper is to propose a novel way of measuring the geometric difference between the desired shape and an actual formed "U" channel. The metric is based upon measuring errors in terms of the significant manufacturing variations. The metric accords with the manually measured errors of the channel set. The shape error metric is then extended to develop a simple empirical, whole-component, springback error measure. The springback error measure combines into one value all the angle springback and side wall curl geometric errors for a single channel. Two trends were observed: combined springback decreases when the blank holder force is increased; and the combined springback marginally decreases when the die radii is increased.

Application of bending under tension test to determine the effect of tool radius and the contact pressure on the coefficient of friction in sheet metal forming

To quantify the frictional behaviour in sheet forming operations, several laboratory experiments which simulate the real forming conditions are performed. The Bending Under Tension Test is one such experiment which is often used to represent the frictional flow of sheet material around a die or a punch radius. Different mathematical representations are used to determine the coefficient of friction in the Bending Under Tension Test. In general the change in the strip thickness in passing over the die radius is neglected and the radius of curvature to thickness ratio is assumed to be constant in these equations. However, the effect of roller radius, sheet thickness and the surface pressure are also omitted in some of these equations. This work quantitatively determined the effect of roller radius and the tooling pressure on the coefficient of friction. The Bending Under Tension Test was performed using rollers with different radii and also lubricants with different properties. The tool radii were found to have a direct influence in the contact pressure. The effect of roller radius on friction was considerable and it was observed that there is a clear relationship between the contact pressure and the coefficient of friction.

Bone geometry in response to long-term tennis playing and its relationship with muscle volume : a quantitative magnetic resonance imaging study in tennis players

The benefit of impact-loading activity for bone strength depends on whether the additional bone mineral content (BMC) accrued at loaded sites is due to an increased bone size, volumetric bone mineral density (vBMD) or both. Using magnetic resonance imaging (MRI) and dual energy X-ray absorptiometry (DXA), the aim of this study was to characterize the geometric changes of the dominant radius in response to long-term tennis playing and to assess the influence of muscle forces on bone tissue by investigating the muscle–bone relationship. Twenty tennis players (10 men and 10 women, mean age: 23.1 ± 4.7 years, with 14.3 ± 3.4 years of playing) were recruited. The total bone volume, cortical volume, sub-cortical volume and muscle volume were measured at both distal radii by MRI. BMC was assessed by DXA and was divided by the total bone volume to derive vBMD. Grip strength was evaluated with a dynamometer. Significant side-to-side differences (P < 0.0001) were found in muscle volume (+9.7%), grip strength (+13.3%), BMC (+13.5%), total bone volume (+10.3%) and sub-cortical volume (+20.6%), but not in cortical volume (+2.6%, ns). The asymmetry in total bone volume explained 75% of the variance in BMC asymmetry (P < 0.0001). vBMD was slightly higher on the dominant side (+3.3%, P < 0.05). Grip strength and muscle volume correlated with all bone variables (except vBMD) on both sides (r = 0.48–0.86, P < 0.05–0.0001) but the asymmetries in muscle parameters did not correlate with those in bone parameters. After adjustment for muscle volume or grip strength, BMC was still greater on the dominant side. This study showed that the greater BMC induced by long-term tennis playing at the dominant radius was associated to a marked increase in bone size and a slight improvement in volumetric BMD, thereby improving bone strength. In addition to the muscle contractions, other mechanical stimuli seemed to exert a direct effect on bone tissue, contributing to the specific bone response to tennis playing.

An experimental investigation of edge strain and bow in roll forming a V-section

V-sections were roll formed from two grades of steel, and the strain on the top and bottom of the strip near the edge was measured using electrical resistance strain gauges. The channels were bent to a radius of 2 and 15 mm along the centerline. The steel strips were of mild and dual phase steel of yield strength 367 MPa and 597 MPa respectively. The longitudinal bow was measured using a 3-dimensional scanning system. The strain measurements were analysed to determine bending and mid-surface strains at the edge during forming. The peak longitudinal edge strain increased with material yield strength for both profile radii. For the 15 mm radius, the bow was larger in the dual phase steel than in the mild steel. For the 2 mm profile radius, the bow was smaller compared with the 15 mm profile radius and it was similar for both steels. It was observed that the difference between the peak longitudinal edge strain and yield strength to Youngs modulus ratio of the material is an important factor in determining longitudinal bow.

Polymeric colorants: Statistical copolymers of indigo building blocks with defined structures

Statistical copolymers of indigo (1a) and N-acetylindigo (1b) building blocks with defined structures were studied. They belong to the class of polymeric colorants. The polymers consist of 5,5′-connected indigo units with keto structure and N-acetylindigo units with uncommon tautomeric indoxyl/indolone (=1H-indol-3-ol/3H-indol-3-one) structure (see 2a and 2b in Fig. 1). They formed amorphous salts of elongated monomer lengths as compared to monomeric indigo. The polymers were studied by various spectroscopic and physico-chemical methods in solid state and in solution. As shown by small-angle-neutron scattering (SANS) and transmission-electron microscopy (TEM), disk-like polymeric aggregates were present in concentrated solutions (DMSO and aq. NaOH soln.). Their thickness and radii were determined to be ca. 0.4 and ca. 80 nm, respectively. From the disk volumes and by a Guinier analysis, the molecular masses of the aggregates were calculated, which were in good agreement with each other. Defined structural changes of the polymer chains were observed during several-weeks storage in concentrated DMSO solutions. The original keto structure of the unsubstituted indigo building blocks reverted to the more flexible indoxyl/indolone structure. The new polymers were simultaneously stabilized by intermolecular H-bonds to give aggregates, preferentially dimers. Both aggregation and tautomerization were reversible upon dissolution. The polymers were synthesized by repeated oxidative coupling of 1,1′-diacetyl-3,3′-dihydroxybis-indoles 5 (from 1,1′-diacetyl-3,3′-bis(acetyloxy)bis-indoles 6) followed by gradual hydrolysis of the primarily formed poly(N,N′-diacetylindigos) 7 (Scheme). N,N′-Diacetylbis-anthranilic acids 9 were isolated as by-products.

Development and measurement properties of a putting skill test for high-level golf

Despite a recent increase in the amount of research investigating performance in golf, a comprehensive putting skill test has not been reported in the peer-reviewed literature. In this study, the Golf Australia Putting Test (GAPT) was developed and a series of measurement properties were assessed. Elite (n = 18) and high-level amateur (HLA; n = 22) participants completed six single putts from various areas on six concentric circles (circle radii = 0.9, 1.5, 3.0, 4.6, 6.1 and 7.6 m). Using a scoring system that rewarded participants for holing putts from longer distances, the maximum score from a single round of the test (i.e. 36 putts) was 27 points. After two rounds of the test were completed by all players, a subsample of participants (elite, n = 15; HLA, n = 7) had their putting performance recorded during tournament play for a period of 90 days to assess criterion (predictive) validity of the test. The reliability, sensitivity and discriminative validity of the GAPT were also assessed. Better agreement between Rounds 1 and 2 scores was noted in the elite group, whilst reliability values were similar for both groups. Further, the GAPT scores were shown to predict players from the elite and high-ability groups with a low classification error. An equation for predicting on-course performance from GAPT scores was also developed. Findings from this study indicate that the GAPT is a valid and reliable tool for high-level players and the GAPT may be used for player evaluation in the field.

Roll-formability of cryo-rolled ultrafine aluminium sheet

Ultrafine-grain aluminium sheet was produced by rolling at cryogenic (CR) and at room temperature (RTR). Commercial purity aluminium plate was reduced in 30 passes from an initial material thickness of 10 mm to a final thickness of 2 mm (80% reduction). Tensile stress and strength were significantly increased while total elongation was drastically reduced. It was found that despite the low tensile elongation both materials are able to accommodate high localised strains in the neck leading to a high reduction in area. The formability of the material was further investigated in bending operations. A minimum bending radius of 6 mm (CR) and 5 mm (RTR) was found and pure bending tests showed homogeneous forming behaviour for both materials. In V-die bending the cryo-rolled material showed strain localisations across the final radius and kinking of the sample. It has been found that even if the total elongation in tension is close to zero leading to early failure in V-die bending, ultra-fine grained and low ductile sheet metals can be roll formed to simple section shapes with small radii using commercial roll forming equipment.

Scalable hierarchical rings based routing to a mobile robot in wireless sensor networks

Location service provides location information of robots to sensors, to enable event reporting. Existing protocols apply partial flooding to trace robots, leading to poor scalability. We propose a novel scalable location service, which applies hierarchical rings to update robot location and guide routing toward it. Each mobile robot creates a set of hierarchical update rings of doubling radii. Whenever the robot leaves its k-th ring, it updates its new location to sensors along its newly defined k-th ring, and re-defines all smaller rings for future decisions. When a sensor needs to route to the mobile robot, it starts searching from its smallest ring and sends location query to the sensors along the ring. If the query fails, the search then extends to the next larger ring, until it intersects an existing update ring, from which the search can be directed towards reported center. The location of destination is updated whenever another more recent ring is intersected. Our scheme guarantees message delivery if robot remains connected to sensors during its move. The theoretical analysis and simulation results demonstrate better scalability than previous protocols for the similar goal. © 2014 IEEE.

Defining marine important bird areas: testing the foraging radius approach

Recent international initiatives have promoted a number of different approaches to identify marine Important Bird and biodiversity Areas (IBAs), which are important areas for foraging, migrating or over-wintering seabirds. The 'Foraging Radius Approach' is one of these and uses known foraging range and habitat preferences to predict the size and location of foraging areas around breeding colonies. Here we assess the performance of the Foraging Radius Approach using GPS tracking data from six seabird species with a variety of foraging modes. For each species we compared the population home-range areas of our six study species with the home-range areas defined using the Foraging Radius Approach. We also assessed whether basic information on depth preferences from tracking data could improve these home-range area estimates. Foraging Radius Approach home-range areas based on maximum foraging radii encompassed the entire population home-range of five out of six of our study species but overestimated the size of the population home-range area in every case. The mean maximum foraging radius overestimated the population home-range areas by a factor of 4-14 for five of the six species whilst the mean foraging radius overestimated the population home-range area for half of the species and underestimated for the rest. In the absence of other data, the Foraging Radius Approach appears to provide a reasonable basis for preliminary marine IBA identification. We suggest that using the mean value of all previously reported maximum foraging radii, informed by basic depth preferences provides the most appropriate prediction, balancing the needs of seabirds with efficient use of marine space.

The SLUGGS survey: a new mask design to reconstruct the stellar populations and kinematics of both inner and outer galaxy regions

Integral field unit spectrographs allow the 2D exploration of the kinematics and stellar populations of galaxies, although they are generally restricted to small fields-of-view. Using the large field-of-view of the DEIMOS multislit spectrograph on Keck and our Stellar Kinematics using Multiple Slits technique, we are able to extract sky-subtracted stellar light spectra to large galactocentric radii. Here, we present a new DEIMOS mask design named SuperSKiMS that explores large spatial scales without sacrificing high spatial sampling. We simulate a set of observations with such a mask design on the nearby galaxy NGC 1023, measuring stellar kinematics and metallicities out to where the galaxy surface brightness is orders of magnitude fainter than the sky. With this technique we also reproduce the results from literature integral field spectroscopy in the innermost galaxy regions. In particular, we use the simulated NGC 1023 kinematics to model its total mass distribution to large radii, obtaining comparable results with those from published integral field unit observation. Finally, from new spectra of NGC 1023, we obtain stellar 2D kinematics and metallicity distributions that show good agreement with integral field spectroscopy results in the overlapping regions. In particular, we do not find a significant offset between our Stellar Kinematics using Multiple Slits and the ATLAS3D stellar velocity dispersion at the same spatial locations.