Computational modelling of metal extrusion and forging processes

The computational modelling of extrusion and forging processes is now well established. There are two main approaches: Lagrangian and Eulerian. The first has considerable complexities associated with remeshing, especially when the code is parallelised. The second approach means that the mould has to be assumed to be entirely rigid and this may not be the case. In this paper, a novel approach is described which utilises finite volume methods on unstructured meshes. This approach involves the solution of free surface non-Newtonian fluid flow equations in an Eulerian context to track the behaviour of the workpiece and its extrusion/forging, and the solution of the solid mechanics equations in the Lagrangian context to predict the deformation/stress behaviour of the die. Test cases for modelling extrusion and forging problems using this approach will be presented.

Case-based retrieval of 3-dimensional shapes for the design of metal castings

This paper describes research into retrieval based on 3-dimensional shapes for use in the metal casting industry. The purpose of the system is to advise a casting engineer on the design aspects of a new casting by reference to similar castings which have been prototyped and tested in the past. The key aspects of the system are the orientation of the shape within the mould, the positions of feeders and chills, and particular advice concerning special problems and solutions, and possible redesign. The main focus of this research is the effectiveness of similarity measures based on 3-dimensional shapes. The approach adopted here is to construct similarity measures based on a graphical representation deriving from a shape decomposition used extensively by experienced casting design engineers. The paper explains the graphical representation and discusses similarity measures based on it. Performance measures for the CBR system are given, and the results for trials of the system are presented. The competence of the current case-base is discussed, with reference to a representation of cases as points in an n-dimensional feature space, and its principal components visualization. A refinement of the case base is performed as a result of the competence analysis and the performance of the case-base before and after refinement is compared.

The tilt casting of titanium aluminides

TiAl castings are prone to various defects including bubbles entrained during the turbulent filling of moulds. The present research has exploited the principles of the Durville tilt casting technique to develop a novel process in which the Induction Skull Melting (ISM) of TiAl alloys in a vacuum chamber has been combined with controlled tilt pouring to achieve the tranquil transfer of the metal into a hot ceramic shell mould. Practical casting equipment has been developed to evaluate the feasibility of this process in parallel with the development of novel software to simulate and optimize it. The PHYSICA CFD code was used to simulate the filling, heat transfer and solidification during tilt pouring using a number of free surface modelling techniques, including the novel Counter Diffusion Method (CDM). In view of the limited superheat, particular attention was paid to the mould design to minimize heat loss and gas entrainment caused by interaction between the counter-flowing metal and gas streams. The model has been validated against real-time X-ray movies of the tilt casting of aluminium and against TiAl blade castings. Modelling has contributed to designing a mould to promote progressive filling of the casting and has led to the use of a parabolic tilting cycle to balance the competing requirements for rapid filling to minimize the loss of superheat and slow filling minimize the turbulence-induced defects.

Modelling the tilt-casting process for the tranquil filling of titanium alloy turbine blades

The tilt-casting method is used to achieve tranquil filling of gamma-TiAl turbine blades. The reactive alloy is melted in a cold crucible using an induction coil and then the complete crucible-mould- running system assembly is rotated through 180degrees to transfer the metal into the mould. The induction current is ramped down gradually as the rotation starts and the mould is preheated to maintain superheat. The liquid metal then enters the mould and the gas within it (argon) escapes through the inlet aperture and through auxiliary vents. Solidification starts as soon the metal enters the mould and it is important to account for this effect to predict and prevent misruns. The rotation rate has to be controlled carefully to allow sufficient time for gas evacuation, but at the same time preserve superheat. This 3-phase system is modelled using the FV method, with a fast implicit numerical scheme used to capture the transient liquid free surface. The enthalpy method is used to model solidification and predict defects such as trapped bubbles, macro-porosity or surface connected porosity. Modeling is used to support an experimental program for the development of a production method for gamma-TiAl blades, with a target length of 40cm. The experiments provide validation for the model and the model in turn optimizes the tilt-casting process. The work is part of the EU project IMPRESS.

Coupled Temperature-Displacement Modelling of Injection Stretch Blow Moulding of PET bottles using Buckley Model

This study presents a fully coupled temperature–displacement finite element modelling of the injection stretch-blow moulding (ISBM) process of polyethylene terephthalate (PET) bottles using ABAQUS with a view to optimising the process conditions. A physically-based material model (Buckley model) was used to predict the mechanical behaviour of PET at temperatures slightly above its glass transition temperature. A model incorporating heat transfer between the stretch rod, the preform and the mould was built using axisymmetric solid elements. Extensive finite element analyses were carried out to predict the deformation, the distribution and history of strain and temperature during ISBM of a 20 g–330 ml bottle, which was made in an in situ test on a Sidel SB06 machine. Comparisons of numerical results with the measurements demonstrate that the model can satisfactorily model the sidewall thickness and material distributions. It is also shown that significant non-linear differentials exist in temperature and strain in both bottle thickness and length directions during the process. This justifies the employment of a volume approach to accurately predict the final mechanical properties of the bottles governed by the orientation and crystallinity which are highly temperature and strain dependent.

Biaxial Characterisation of Materials for Thermoforming and Blow Moulding

During free surface moulding processes such as thermoforming and blow moulding heated polymer materials are subjected to rapid biaxial deformation as they are drawn into the shape of a mould. In the development of process simulations it is therefore essential to be able to accurately measure and model this behaviour. Conventional uniaxial test methods are generally inadequate for this purpose and this has led to the development of specialised biaxial test rigs. In this paper the results of several programmes of biaxial tests conducted at Queen’s University are presented and discussed. These have included tests on high impact polystyrene (HIPS), polypropylene (PP) and aPET, and the work has involved a wide variety of experimental conditions. In all cases the results clearly demonstrate the unique characteristics of materials when subjected to biaxial deformation. PP draws the highest stresses and it is the most temperature sensitive of the materials. aPET is initially easier to form but exhibits strain hardening at higher strains. This behaviour is increased with increasing strain rate but at very high strain rates these effects are increasingly mollified by adiabatic heating. Both aPET and PP (to a lesser degree) draw much higher stresses in sequential stretching showing that this behaviour must be considered in process simulations. HIPS showed none of these effects and it is the easiest material to deform.

Skin bradykinin-related peptides (BRPs) and their biosynthetic precusors (kininogens): comparisons between various taxa of Chinese and North American ranid frogs.

Bradykinins and related peptides (BRPs) occur in the defensive skin secretions of many amphibians. Here we report the structures of BRPs and their corresponding biosynthetic precursor cDNAs from the Chinese brown frog, Rana chensinensis, and the North American leopard frog, Lithobates pipiens. R. chensinensis skin contained four transcripts each encoding a different kininogen whose organizations and spectrum of encoded BRPs were similar to those reported for the pickerel frog, Lithobates palustris. In contrast, from L. pipiens, a single skin kininogen was cloned whose structural organization and spectrum of mature BRPs were similar to those reported for the Chinese piebald odorous frog, Huia schmackeri. These data also implied that the endogenous precursor processing proteases in each species pair have identical site-directed specificities, which in part may be dictated by the primary structures of encoded BRPs. Thus the spectra of skin BRPs and the organization of their biosynthetic precursors are not consistent with recent taxonomy. The natural selective pressures that mould the primary structures of amphibian skin secretion peptides are thought to be related to the spectrum of predators encountered within their habitats. Thus similarities and differences in skin bradykinins may be reflective of predator spectra rather than indicative of species relatedness.

Mechanical behaviour of unsaturated kaolin (with isotropic and anisotropic stress history). Part 1: wetting and compression behaviour

Over the last 40 years considerable progress has been made in understanding the complex behaviour of unsaturated soils. Research using constitutive modelling has extended the critical state framework and the concept of yielding in saturated soils to encompass unsaturated soils experiencing suction. However, validation testing of the framework for unsaturated soils has shown disagreement with the basic propositions. The main reason for this disparity is the anisotropic properties of the soil specimens tested as a result of preparation using one-dimensional compaction. The paper describes the detailed testing carried out to justify this statement. As part of the work presented, samples of unsaturated kaolin were prepared using isotropic compression. The suctions in these samples were reduced to predefined values by wetting under low isotropic loading. The pore size distributions, the pressure–volume relationships and yielding under subsequent isotropic loading are compared with tests on samples prepared by statically compressing kaolin into a one-dimensional compaction mould. The anisotropically compressed samples had initial water contents and specific volumes similar to those of the isotropically prepared samples and were also tested under reducing suctions; they exhibited distinctly different behaviour when tested under similar conditions. The results obtained from the isotropically prepared and tested samples have shown, probably for the first time, the existence of a unique normal compression surface that is not dependent on the initial conditions of the samples. The shape of the loading–collapse (LC) yield locus is shown to be different from the generally accepted form.

The influence of reusing ‘Formtex’ controlled permeability

The effects of the reuse of ‘Formtex’ Controlled Permeability Formwork (CPF) liner on strength and durability properties of concrete were investigated at two different water-cement ratios and the results are reported in this paper. Test blocks were cast using the CPF on one side and impermeable formwork (IF) on the opposite side of the mould so that direct comparisons could be made between the two. The strength was assessed using the Limpet pulloff tester and both the air permeability and the water absorption (sorptivity) were measured using the Autoclam Permeability System. Both these instruments measured the ‘covercrete’ properties. In addition, cores cut from the test specimens were subjected to an accelerated carbonation test and a chloride exposure test. The results showed that the ‘Formtex’ CPF increases the surface strength and the durability of concrete compared to the IF. There was an almost complete elimination of blowholes. The permeability of concrete decreased and its resistance to the ingress of both carbon dioxide and chlorides increased when CPF was used. The beneficial effects of the Formtex CPF were most evident in concrete of higher water-cement ratio. With the reuse of the Formtex liner twice, that is a total of three uses, the performance of the CPF to improve the properties of concrete remained almost the same. In this research the CPF liner was cleaned thoroughly between each use, which must be adhered to for site applications for reproducing the beneficial effects observed in the laboratory.

Dvořák, his Librettists, and the Working Libretto for ‘Armida’

From the late 1860s, opera for Dvorák, along with many composers of the Czech national revival, was an abiding preoccupation. This article examines Dvorak’s relationship with his librettists, his approach to their texts, and the extent to which he was prepared to mould their content. While there is no surviving correspondence between Dvorák and the librettist of his last opera, Jaroslav Vrchlický, a copy of the libretto of Armida with annotations in both Vrchlický’s and Dvorák’s hands was found in 2007 among the writer’s papers. Although Dvorák’s stage sense has often been called into question, it is clear that his interventions in the libretto of Armida, in the first and last acts in particular, show a practical, theatrical approach that did much to enhance the dramatic impact of Armida’s first entry and the final chorus of the opera.

Melt-compounded nanocomposites of titanium dioxide atomic-layer-deposition-coated polyamide and polystyrene powders

Polyamide and polystyrene particles were coated with titanium dioxide films by atomic layer deposition (ALD) and then melt-compounded to form polymer nanocomposites. The rheological properties of the ALD-created nanocomposite materials were characterized with a melt flow indexer, a melt flow spiral mould, and a rotational rheometer. The results suggest that the melt flow properties of polyamide nanocomposites were markedly better than those of pure polyamide and polystyrene nanocomposites. Such behavior was shown to originate in an uncontrollable decrease in the polyamide molecular weight, likely affected by a high thin-film impurity content, as shown in gel permeation chromatography (GPC) and scanning electron microscope (SEM) equipped with an energy-dispersive spectrometer. Transmission electron microscope image showed that a thin film grew on both studied polymer particles, and that subsequent melt-compounding was successful, producing well dispersed ribbon-like titanium dioxide with the titanium dioxide filler content ranging from 0.06 to 1.12wt%. Even though we used nanofillers with a high aspect ratio, they had only a minor effect on the tensile and flexural properties of the polystyrene nanocomposites. The mechanical behavior of polyamide nanocomposites was more complex because of the molecular weight degradation. Our approach here to form polymeric nanocomposites is one way to tailor ceramic nanofillers and form homogenous polymer nanocomposites with minimal work-related risks in handling powder form nanofillers. However, further research is needed to gauge the commercial potential of ALD-created nanocomposite materials. Copyright (C) 2011 John Wiley & Sons, Ltd.

Sense and sensibility: The role of business incubator client advisors in assisting high-technology entrepreneurs to make sense of investment readiness status

For high-technology entrepreneurs, attaining an appropriate level of investment to support new ventures is challenging as substantial investment is usually required prior to revenue generation. Consequently, entrepreneurs must present their firms as investment ready in the context of an uncertain market response and an absence of any trading history. Gaining tenancy within a business incubator can be advantageous to this process given that placement enhances entrepreneurial contact with potential investors whilst professional client advisors (CAs) use their expertise to assist in the development of a credible business plan. However, for the investment proposal to be successful, it must make sense to fund managers despite their lack of technological expertise and product knowledge. Thus, this article explores how incubator CAs and entrepreneurs act in concert to mould innovative ideas into plausible business plans that make sense to venture fund investors. To illustrate this process, we draw upon empirical evidence which suggests that CAs act as sense makers between venture fund managers (VFMs) and high-technology entrepreneurs, yet their role and influence appears undervalued. These findings have implications for entrepreneurial access to much needed funding and also for the identification of investment opportunities for VFMs. © 2011 Taylor & Francis.

Strategic Spatial Planning in Berlin–Brandenburg: A Requiem for Balanced Development?

This practice review examines Berlin–Brandenburg’s new strategic spatial planning framework and considers, in particular, whether balanced development in this context is now simply a neoliberal fig leaf and mantra acting as policy cover for more pragmatic accommodations in harsh times. The article concludes that such a judgement would be too harsh with the concept continuing to mould creative engagement by decision-makers.

Experimental Investigation of Stretch Blow Molding, Part 2: Analysis of Process Variables, Blowing Kinematics, and Bottle Properties

The work presented in this paper takes advantage of newly developed instrumentation suitable for in process monitoring of an industrial stretch blow molding machine. The instrumentation provides blowing pressure and stretch rod force histories along with the kinematics of polymer contact with the mould wall. A Design of Experiments pattern was used to qualitatively relate machine inputs with these process parameters and the thickness distribution of stretch blow molded PET (polyethylene terephtalate) bottles. Material slippage at the mold wall and thickness distribution is also discussed in relation to machine inputs. The key process indicators defined have great potential for use in a closed loop process control system and for validation of process simulations.

Modelling and Instrumentation of Stretch Blow Moulding

The injection stretch blow moulding process is used to manufacture PET containers used in the soft drinks and carbonated soft drinks industry. The process consists of a test tube like specimen known as a preform which is heated, stretch and blown into a mould to form the container. This research is focused on developing a validated simulation of the process thus enabling manufacturers to design their products in a virtual environment without the need to waste time, material and energy. The simulation has been developed using the commercial FEA package Abaqus and has been validated using state of the art data acquisition system consisting of measurements for preform temperature (inner and outer wall) using a device known as THERMOscan (Figure 1), stretch rod force and velocity, internal pressure and air temperature inside the preform using an instrumented stretch rod and the?exact?timing of when the preform touches the mould wall using contact sensors.? In addition, validation studies have also been performed by blowing a perform without a mould and using high sped imaging technology in cooperation with an advanced digital image correlation system (VIC 3D) to provided new quantitative information on the behaviour of PET during blowing.? The approach has resulted in a realistic simulation in terms of accurate input parameters, preform shape evolution and prediction of final properties.