A deep learning model for controlling the galvanizing process in a production line

In the industry of steelmaking, the process of galvanizing is a treatment which is applied to protect the steel from corrosion. The air knife effect (AKE) occurs when nozzles emit a steam of air on the surfaces of a steel strip to remove excess zinc from it. In our work we formalized the problem to control the AKE and we implemented, with the R&D dept.of MarcegagliaSPA, a DL model able to drive the AKE. We call it controller. It takes as input the tuple : a tuple of the physical conditions of the process line (t,h,s) with the target value of the zinc coating (c); and generates the expected tuple of (pres and dist) to drive the mechanical nozzles towards the (c). According to the requirements we designed the structure of the network. We collected and explored the data set of the historical data of the smart factory. Finally, we designed the loss function as sum of three components: the minimization between the coating addressed by the network and the target value we want to reach; and two weighted minimization components for both pressure and distance. In our solution we construct a second module, named coating net, to predict the coating of zinc resulting from the AKE when the conditions are applied to the prod. line. Its structure is made by a linear and a deep nonlinear “residual” component learned by empirical observations. The predictions made by the coating nets are used as ground truth in the loss function of the controller. By tuning the weights of the different components of the loss function, it is possible to train models with slightly different optimization purposes. In the tests we compared the regularization of different strategies with the standard one in condition of optimal estimation for both; the overall accuracy is ± 3 g/m^2 dal target for all of them. Lastly, we analyze how the controller modeled the current solutions with the new logic: the sub-optimal values of pres and dist can be optimize of 50% and 20%.

Analisi del comportamento a caldo dell'acciaio AISI - H11 per la stima della vita utile di matrici per estrusione

The effect of process parameters on the creep-fatigue behavior of a hot-work tool steel for aluminum extrusion die was investigated through a technological test in which the specimen geometry resembled the mandrel of a hollow extrusion die. Tests were performed on a Gleeble thermomechanical simulator by heating the specimen using joule’s effect and by applying cyclic loading up to 6.30 h or till specimen failure. Displacements during the tests at 380, 490, 540 and 580°C and under the average stresses of 400, 600 and 800 MPa were determined. In the first set of test a dwell time of 3 min was introduced during each of the tests to understand the creep behavior. The results showed that the test could indeed physically simulate the cyclic loading on the hollow die during extrusion and reveal all the mechanisms of creep-fatigue interaction. In the second set a pure fatigue laod were induced and in the third set a static creep load were induced in the specimens. Furher type of tests, finite element and microstructural analysis were presented.

Hot wire manufacturing and resolution effects in high Reynolds number flows

Lo studio della turbolenza è di fondamentale importanza non solo per la fluidodinamica teorica ma anche perchè viene riscontrata in una moltitudine di problemi di interesse ingegneristico. All'aumentare del numero di Reynolds, le scale caratteristiche tendono a ridurre le loro dimensioni assolute. Nella fluidodinamica sperimentale già da lungo tempo si è affermata l'anemometria a filo caldo, grazie ad ottime caratteristiche di risoluzione spaziale e temporale. Questa tecnica, caratterizzata da un basso costo e da una relativa semplicità, rende possibile la realizzazione di sensori di tipo artigianale, che hanno il vantaggio di poter essere relizzati in dimensioni inferiori. Nonostante l'ottima risoluzione spaziale degli hot-wire, infatti, si può verificare, ad alto numero di Reynolds, che le dimensioni dell'elemento sensibile siano superiori a quelle delle piccole scale. Questo impedisce al sensore di risolvere correttamente le strutture più piccole. Per questa tesi di laurea è stato allestito un laboratorio per la costruzione di sensori a filo caldo con filo di platino. Sono in questo modo stati realizzati diversi sensori dalle dimensioni caratteristiche inferiori a quelle dei sensori disponibili commercialmente. I sensori ottenuti sono quindi stati testati in un getto turbolento, dapprima confrontandone la risposta con un sensore di tipo commerciale, per verificarne il corretto funzionamento. In seguito si sono eseguite misure più specifiche e limitate ad alcune particolari zone all'interno del campo di moto, dove è probabile riscontrare effetti di risoluzione spaziale. Sono stati analizzati gli effetti della dimensione fisica del sensore sui momenti statistici centrali, sugli spettri di velocità e sulle funzioni di densità di probabilità.

A numerical study of temperature effects on hot wire measurements inside turbulent channel flows

A way to investigate turbulence is through experiments where hot wire measurements are performed. Analysis of the in turbulence of a temperature gradient on hot wire measurements is the aim of this thesis work. Actually - to author's knowledge - this investigation is the first attempt to document, understand and ultimately correct the effect of temperature gradients on turbulence statistics. However a numerical approach is used since instantaneous temperature and streamwise velocity fields are required to evaluate this effect. A channel flow simulation at Re_tau = 180 is analyzed to make a first evaluation of the amount of error introduced by temperature gradient inside the domain. Hot wire data field is obtained processing the numerical flow field through the application of a proper version of the King's law, which connect voltage, velocity and temperature. A drift in mean streamwise velocity profile and rms is observed when temperature correction is performed by means of centerline temperature. A correct mean velocity pro�le is achieved correcting temperature through its mean value at each wall normal position, but a not negligible error is still present into rms. The key point to correct properly the sensed velocity from the hot wire is the knowledge of the instantaneous temperature field. For this purpose three correction methods are proposed. At the end a numerical simulation at Re_tau =590 is also evaluated in order to confirm the results discussed earlier.

Effetti della risoluzione spaziale nella stima della dissipazione con sensore hot-wire

L'obiettivo primario di questo elaborato di tesi è quello di stimare l'effetto della risoluzione spaziale e quindi della lunghezza finita del sensore di un anemometro a filo caldo, sul calcolo delle derivate che contribuiscono a valutare la dissipazione.