A finite element simulation of micro-mechanical frictional behaviour in metal forming

Friction is a critical factor for sheet metal forming (SMF). The Coulomb friction model is usually used in most finite element (FE) simulation for SMF. However, friction is a function of the local contact deformation conditions, such as local pressure, roughness and relative velocity. Frictional behaviour between contact surfaces can be based on three cases: boundary, hydrodynamic and mixed lubrication. In our microscopic friction model based on the finite element method (FEM), the case of dry contact between sheet and tool has been considered. In the view of microscopic geometry, roughness depends upon amplitude and wavelength of surface asperities of sheet and tool. The mean pressure applied on the surface differs from the pressure over the actual contact area. The effect of roughness (microscopic geometric condition) and relative speed of contact surfaces on friction coefficient was examined in the FE model for the microscopic friction behaviour. The analysis was performed using an explicit FE formulation. In this study, it was found that the roughness of deformable sheet decreases during sliding and the coefficient of friction increases with increasing roughness of contact surfaces. Also, the coefficient of friction increases with the increase of relative velocity and adhesive friction coefficient between contact surfaces.

Skin friction coefficient on a yarn package surface in ring spinning

The skin friction coefficient on the surface of a rotating yarn package affects the power required to drive the package. This paper examines the relationship between the skin friction coefficient on the package surface and its diameter and rotating speed, based on the fundamentals of aerodynamics and the experimental results of power consumption. Skin friction coefficients on the surfaces of an airplane, car top, and yarn package are discussed. The results indicate that the skin friction coefficient on the package surface without hairiness depends on the package diameter and spindle speed only. The skin friction coefficient on the yarn package surface is about three times that on the top surface of a car, and is about twenty times that on an airplane surface. The power consumed to overcome skin friction drag is more than that consumed to drive the spindle if the spindle speed is very slow. However, the situation reverses when the spindle speed is fast.

Influence of the geometry of an immersed steel workpiece on mass transfer coefficient in a chemical heat treatment fluidised bed

The mass transfer during carburising in a fluidised bed and in a steel workpiece has been studied experimentally in this work. This involved carburising experiment in an electrically heated fluidised bed at 900–970°C with natural gas and air as the atmosphere. A steel workpiece was designed to provide a range of carbon transfer surfaces of different geometries in the fluidised bed, and the carbon transfer coefficient was measured at these surfaces. The carbon transfer coefficient was determined from the carbon distribution within the diffusion layer of the sample. An empirical relationship of the carbon potential as a function of carburising atmosphere, bed temperature and fluidising velocity was determined, based on the understanding of the mass transfer mechanism and analysis of the experimental results.

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.

Carburising and carbon transfer coefficient in a fluidised bed furnance

The carburising of a steel workpiece with complex geometry in a fluidised bed hasbeen studied experimentally. This involved carburising experiment in an electrically heated fluidised bed at 900 - 970°C with natural gas and air as the atmosphere. The carbon transfer coefficient at the workpiece surface and diffusivity within the workpiece were determined from the carbon distribution within the diffusion layer of the sample. A reverse method and the Levenberg-Marquardt algorithm were used in the calculations. The methodology of the reverses method to extract the carbon transfer coefficient and diffusivity is also discussed in some detail.

Measurement of the mass transfer coefficient at workpiece surfaces in heat treatment furnaces

The mass (e.g. carbon) transfer coefficient at a workpiece surface is an important kinetic factor to control the heat treatment process of the workpiece and to evaluate heat treatment equipment. The coefficient can be calculated from the carbon concentration at the surface of a sample carburized in a carburizing furnace for a given time. Two common measurement methods which use a thin plate and employ a component as samples respectively are evaluated and compared for sensitivity and uncertainty. The comparison shows that the use of a component produces higher measurement precision and also has the advantage in measuring the carbon transfer coefficients at different treated positions. This method is then extended and discussed methodologically. Also two equations are proposed to calculate the carbon transfer coefficient and its uncertainty, respectively. This method is also applied to measure the carbon transfer coefficient in a fluidized bed heat treatment furnace.

Variation of fibre diameter coefficient of variation and fibre curvature across mohair fleeces: Implications for animal selection, genetic selection and fleece evaluation

The presentwork aimed to determine howthe average fibre diameter coefficient of variation (CVD) and fibre curvature (FC) differences between nine sampling sites vary between sex and flock, to identify differences in variability between sampling sites as a result of between animal and between sire variability and to determine correlations between sampling sites in between animal and between sire variability. Australian Angoras (n = 313) from two farms in southern Australia were sampled at 12 and 18 months of age at nine sites (mid side, belly, brisket, hind flank, hip, hock, mid back, neck, shoulder). Staples were taken prior to shearing at skin level and CVD and FC determined. For each shearing, differences in CVD and FC between sampling sites, how these differences were affected by farm, sex, and sire, and the covariance between sites for sire and individual animal effects were investigated by restricted maximum likelihood (REML) analyses. The median mid side CVD at 12 and 18 months of age ranged from 23.6 to 25.1% but the actual range was 16.8–34.2%. The median mid side FC at 12 and 18 months of age ranged from 14.4 to 18.6◦/mm but the actual range was 10.5–26.3◦/mm. The general pattern for CVDwas for the mid back, hip and neck sites to have similar CVD, the brisket, hind flank and hock sites to have larger CVD and the belly to have smaller CVD than the mid side site. The between animal variation for CVD was lowest at the mid back site. This implies that the mid back would be the most effective site for between animal selection for CVD. Heritabilities for CVD (range at 18 months 0.18–0.30) were only about half the heritabilities for mean fibre diameter in the same study. There was a marked anterior–posterior increase in FC at both farms and with both ages. The results give no clear indication of the best site for between animal selection for FC, other than that the hock should be avoided. Heritabilities for FC are moderate to high (range at 18 months 0.44–0.77) and the genetic correlations are high except for the hock. Thus genetic selection for FC at any site, other than the hock, should be effective for changing FC over the entire fleece. There was more variability between animals than between sites and sires. These results are put into context with associated research on variation in mean fibre diameter and staple length.

Hydrodynamic flow focusing to study the isolated effects of the flow components

Biological fluids such as blood, proteins and DNA solutiosn moving within fluidic channels can potentially be exposed to high level of shear, extension or mixed stress, either in vitro such as industrial processing of blood products or in vivo such as ocurrs in some pathological conditions. This exposure to a high level of strain can trigger some reactions. In most of the cases the nature of the flow is mixed with shear and extensional components. The ability ot isolate the effects of each component is critical in order to understand the mechanisms behind the reactions and potentially prevent them. Applying hydrodynamic flow focusing, we present in this investigation the characterization of microchannels that allow study of the regions of high shear or high extension strain rate. Micro channels were fabricated in polydimethyl siloxane (PDMS)  using standard soft-lithography techniques with a photolithographically patterned mold. Characterization of the regions with high shear and high extension strain rate is presented. Computational Fluid Dynamics (CFD) simulations in three dimensions have been carried out to gain more detailed local flow information, and the results have been validated experimentally. A comparison between the numerical models and experiment and is presented. The advantages of microfluidic flow focusing in the study  of the effects of shear and extension strain rates for biological fluids are outlined.

3D hydrodynamic analysis of a biomimetic robot fish

This paper presents a three-dimensional (3D) computational fluid dynamic simulation of a biomimetic robot fish. Fluent and user-defined function (UDF) is used to define the movement of the robot fish and the Dynamic Mesh is used to mimic the fish swimming in water. Hydrodynamic analysis is done in this paper too. The aim of this study is to get comparative data about hydrodynamic properties of those guidelines to improve the design, remote control and flexibility of the underwater robot fish.

The 'wimple' : rippled deformation of a fluid drop caused by hydrodynamic and surface forces during thin film drainage

It is well-known that hydrodynamic pressures in a thin draining liquid film can cause inversion of the curvature of a drop or bubble surface as it approaches another surface, creating a so-called “dimple”. Here it is shown that a more complicated rippled shape, dubbed a “wimple”, can be formed if a fluid drop that is already close to a solid wall is abruptly pushed further toward it. The wimple includes a central region in which the film remains thin, surrounded by a ring of greater film thickness that is bounded at the outer edge by a barrier rim where the film is thin. This shape later evolves into a conventional dimple bounded by the barrier rim, which then drains in the normal way. During the evolution from wimple to dimple, some of the fluid in the thicker part of the film ring flows toward the central region before eventually draining in the opposite direction. Although the drop is pressed toward the wall, the central part of the drop moves away from the wall before approaching it again. This is observed even when the inward push is too small to create a wimple.