Kartongin fysikaalisten ominaisuuksien vaikutus muovautuvuuteen

Työn tavoitteena oli kehittää menetelmä, jolla voitaisiin arvioida veto-ominaisuuksien avulla konvertointikoneen prässäysnopeuden ja muottien lämpötilan vaikutuksia kartongin muovautuvuuteen. Kirjallisuusosassa käsiteltiin kartongin muovautuvuuteen vaikuttavia ominaisuuksia sekä vetolujuuteen vaikuttavia tekijöitä. Lisäksi käsiteltiin kosteuden vaikutusta muovautuvuuteen sekä esiteltiin vuokakonvertointiprosessin periaate ja muovin sekä kartongin käyttäytymisen erot konvertointiprosessissa. Kokeellinen osa jakaantui kolmeen osaan. Esikokeissa tutkittiin laboratoriomittauksilla vetonopeuden ja kosteuden muutosten vaikutusta erilaisten kaupallisten kartonkimateriaalien vetolujuuteen ja murtovenymään. Tulosten perusteella valittiin prässäysnopeudet ja kosteustaso 2D- testauslaitteella suoritettuihin esi-pilot-mittakaavan kokeisiin sekä varsinaiseen pilot-koeajoon. Pilot-koeajossa pyrittiin arvioimaan prässäysnopeuden ja muottien lämpötilan vaikutuksia muovautuvuuteen vetolujuusarvojen avulla. Prässäysnopeudella ja vetolujuuslaitteen nopeudella ei havaittu yhteneväisyyksiä, jotta voitaisiin arvioida kartongin muovautuvuutta. Muovautuvuutta voidaan kuitenkin arvioida epäonnistuneisuusluvulla, jonka laskentapa kehitettiin työn aikana. Epäonnistuneisuusluku kuvaa hyvin kartongin muovautuvuutta ja on menetelmänä helppo, mutta sen heikkoutena on repeämien mittaamisen aiheuttama epätarkkuus. Esikokeissa havaittiin myös muovipäällysteiden veto-ominaisuuksien vastaavan kartongin ominaisuuksia 65 %:n suhteellisessa kosteudessa, jonka valittiin siten olevan optimaalinen olosuhde pilot-mittakaavan koeajoihin.

Press forming of paperboard – advancement of converting tools and process control

Press forming is nowadays one of the most common industrial methods in use for producing deeper trays from paperboard. Demands for material properties like recyclability and sustainability have increased also in the packaging industry, but there are still limitations related to the formability of paperboard. A majority of recent studies have focused on material development, but the potential of the package manufacturing process can also be improved by the development of tooling and process control. In this study, advanced converting tools (die cutting tools and the press forming mould) are created for production scale paperboard tray manufacturing. Also monitoring methods that enable the production of paperboard trays with enhanced quality, and can be utilized in process control are developed. The principles for tray blank preparation, including creasing pattern and die cutting tool design are introduced. The mould heating arrangement and determination of mould clearance are investigated to improve the quality of the press formed trays. The effect of the spring back of the tray walls on the tray dimensions can be managed by adjusting the heat-related process parameters and estimating it at the mould design stage. This enables production speed optimization as the process parameters can be adjusted more freely. Real-time monitoring of pressing force by using multiple force sensors embedded in the mould structure can be utilized in the evaluation of material characteristics on a modified production machinery. Comprehensive process control can be achieved with a combination of measurement of the outer dimensions of the trays and pressing force monitoring. The control method enables detection of defects and tracking changes in the material properties. The optimized converting tools provide a basis for effective operation of the control system.

Hitsatun alumiinirakenteen suunnittelu

Alumiiniseosten käyttö konstruktiomateriaalina lisääntyy johtuen sen lukuisista variaatioista lujuuden ja muovattavuuden suhteen. Alumiinin keveys on merkittävä kilpailuetu teräkseen nähden. Alumiiniseosten hitsattavuus on parantunut hitsausmenetelmien kehittyessä. Uusilla menetelmillä lämmöntuontia hallitaan paremmin, kuten myös alumiinin huokoisuutta sekä lujuuden laskua hitsauksen yhteydessä. Tässä diplomityössä tutkitaan alumiinin metallurgiaa, hitsausmenetelmiä, sekä alumiinin ja teräksen sekaliitoksen toteutusta. Tutkimuksella pyritään tekemään hitsatun alumiinirakenteen suunnittelua ymmärrettävämmäksi. SFS-EN standardit antavat perustuksen alumiinirakenteen suunnittelulle. Tässä diplomityössä tehdään suunnitteluesimerkki hitsatun alumiinirakenteen hitsien suunnittelusta. Suunnitteluesimerkissä tutkitaan alumiiniseoksen lujuuden laskua hitsattaessa, ja etsitään standardien antamia ratkaisuja toimivan hitsatun rakenteen toteuttamiseksi.

Factors Affecting Runnability of Press Forming Equipment

The growth of the food packaging industry has raised more interest in bio-based fibre packing. The use of petroleum based packages is unfriendly to the environment while bio-based is a sustainable option for food packing. In this Master Thesis the aim was to discover how the press forming machineries runnability is affected by parameters of the press and how it also affects formability of paperboard trays. Familiarisation of the working operation parameters was done with the KAMA ST 75 flat-bed die cutting machine and the VP3-70 mould press. Some small test runs of moulding trays where done to get acquainted to the adjustment parameters of the machines. Literature study was done on how paperboards physical properties react to the forces applied during press forming. The study of what kind of defects to the paperboard tray might occur during forming process and the causes for these defects. Also how the parameters of the press forming machine affects formability of the tray. Maintenance procedures was done to the press forming machine to enhance the reliably of production process. Tool alignment measurement was done to determine proper alignment. Laboratory test of the physical properties of the test material was done to find any connection to how the test material performs in press forming. An evaluation criterion was made to evaluate the dimensions and defects of the tray. From the test result a conclusion can be drawn on how the parameters of the press forming process affect the paperboard material. Based on the results the adjustment the parameters of moulding machines to the mechanical properties of paperboard it is possible to produce high quality fibre passed trays for the food packaging industry.

Experimental and computational investigation of the roll forming process

One of the first questions to consider when designing a new roll forming line is the number of forming steps required to produce a profile. The number depends on material properties, the cross-section geometry and tolerance requirements, but the tool designer also wants to minimize the number of forming steps in order to reduce the investment costs for the customer. There are several computer aided engineering systems on the market that can assist the tool designing process. These include more or less simple formulas to predict deformation during forming as well as the number of forming steps. In recent years it has also become possible to use finite element analysis for the design of roll forming processes. The objective of the work presented in this thesis was to answer the following question: How should the roll forming process be designed for complex geometries and/or high strength steels? The work approach included both literature studies as well as experimental and modelling work. The experimental part gave direct insight into the process and was also used to develop and validate models of the process. Starting with simple geometries and standard steels the work progressed to more complex profiles of variable depth and width, made of high strength steels. The results obtained are published in seven papers appended to this thesis. In the first study (see paper 1) a finite element model for investigating the roll forming of a U-profile was built. It was used to investigate the effect on longitudinal peak membrane strain and deformation length when yield strength increases, see paper 2 and 3. The simulations showed that the peak strain decreases whereas the deformation length increases when the yield strength increases. The studies described in paper 4 and 5 measured roll load, roll torque, springback and strain history during the U-profile forming process. The measurement results were used to validate the finite element model in paper 1. The results presented in paper 6 shows that the formability of stainless steel (e.g. AISI 301), that in the cold rolled condition has a large martensite fraction, can be substantially increased by heating the bending zone. The heated area will then become austenitic and ductile before the roll forming. Thanks to the phenomenon of strain induced martensite formation, the steel will regain the martensite content and its strength during the subsequent plastic straining. Finally, a new tooling concept for profiles with variable cross-sections is presented in paper 7. The overall conclusions of the present work are that today, it is possible to successfully develop profiles of complex geometries (3D roll forming) in high strength steels and that finite element simulation can be a useful tool in the design of the roll forming process.

Fabricação de malha de trama utilizada como pré-formas na indústria de compósitos e avaliação das propriedades mecânicas

In the manufacture of composite, textile materials are being used as reinforcement. Generally, the combination of the matrix with the textile material in the form of fibres or yarns is used depending on their distribution in the web. In the present work, in place of fibres or yarns, a knitted structure in the form of the final product which is defined as preform. The preform is weft knit manufactured with polyester filaments. In the manufacture of composite, polyester resin was used as matrix. The physical and mechanical properties as well as the formability of the weft knit were analysed. The physical and mechanical properties as well as the formability of the knitted structure were analysed. The results obtained on the analysis show that the courses and wales of the weft knit structure and the tensile properties help the formability of the structure and the impregnation of the resin. It could be clearly observed that composite structure in the direction of the courses support more tension than in the direction of the wales. In relation to the three points flexural tests it was possible to note that there was more flexion in the direction of wales, what was expected. It was also possible to note that there are other advantages such as reduction in the loss of materials used, homogeneity in the distribution of the knitted structure in the mould, reduction in the preparation time and also in the reduction in the cost of manufacture

Ferroelectric ceramic/polymer composite for measuring X-ray intensity in the ortovoltage range

Pyroelectric sensors work as a thermal transducer converting the non-quantified thermal flux into the output measurable quantity of electrical charge, voltage or current. Ferroelectric ceramics and ferroelectric polymers have been extensively used as thermal detectors. More recently the research in the field of pyroelectricity has been concentrated on discovering materials with higher figures of merit (FOM), which means better sensing materials. Composite materials obtained with ferroelectric ceramics embedded in polymer host have received great attention because of their formability, mechanical resistance and the possibility to change their dielectric property varying the volume fraction of ceramic particles. In this work composite films made of modified lead titanate (PZ34) and poly(ether-ether-ketone) (PEEK) were characterized and used as sensing element to measure X-ray intensity in the ortovoltage range (120 - 300 kVp). The sensor response varies from 2.70 V to 0.80 V in the energy fluency range of 6.30 to 37.20 W/m(2). Furthermore the absorbed energy was analyzed as a function of the ionizing energy. The results indicate that the PZ34/PEEK composite with 60/40 vol.% can be useful to monitor X-ray radiation therapy.

Mechanical behaviour of strain aged dual phase steels

Dual phase steels, characterised by good formability and excellent surface finish, are suitable for applications where processing involves cold deformation. In this context an investigation has been conducted into the cold deformation aging susceptibility of carbon steel API-5L-B and microalloyed steel API-5L-X52, both with dual phase microstructures. Changes in mechanical properties such as phase microhardness, ultimate tensile strength, and yield strength in both types of steel were observed at aging temperatures of 25, 80, and 150°C. This aging is associated with dislocation structures formed on ferrite grains in the vicinity of ferrite/martensite interfaces during intercritical treatments, which become preferential sites for solute atom diffusion. © 1999 IoM Communications Ltd.

Piezoelectric composite film for acoustic emission detection

The continuous technological advances require materials with properties that conventional material cannot display. Material property combinations are being the focus to the development of composite materials, which are considered a multiphase material that exhibits properties of the constituent phases. One interesting material to be studied as sensing material is the composite made of ferroelectric ceramic and polymeric matrix as a two-phases composite material. In that case, the combinations properties intended are the high piezo and pyroelectric activities of the dense ceramic with the impact resistance, flexibility, formability and low densities of the polymer. Using the piezoelectric property of the composite film, it can be used to detect acoustic emission (AE), which is a transient elastic wave generated by sudden deformation in materials under stress. AE can be applied for evaluating the health of structures in a nondestructive way and without any lapse of time. The preliminary result indicates that the composite Pz34/PEEK can be used as sensing material for nondestructive evaluation. ©2009 IEEE.

Caracterização metalográfica de um aço de fases complexas (CP)

Pós-graduação em Engenharia Mecânica - FEG

Estudo do envelhecimento após deformação em um aço complex phase

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Polymer Matrix-Based Piezoelectric Composite for Structural Health Monitoring

Structural health monitoring (SHM) refers to the procedure of assessing the structure conditions continuously so it is an alternative to conventional nondestructive evaluation (NDE) techniques [1]. With the growing developments in sensor technology acoustic emission (AE) technology has been attracting attention in SHM applications. AE are characterized by waves produced by the sudden internal stress redistribution caused by the changes in the internal structure, such as fatigue, crack growth, corrosion, etc. Piezoelectric materials such as Lead Zirconate Titanate (PZT) ceramic have been widely used as sensor due to its high electromechanical coupling factor and piezoelectric d coefficients. Because of the poor mechanical characteristic and the lack in the formability of the ceramic, polymer matrix-based piezoelectric composites have been studied in the last decade in order to obtain better properties in comparison with a single phase material. In this study a composite film made of polyurethane (PU) and PZT ceramic particles partially recovered with polyaniline (PAni) was characterized and used as sensor for AE detection. Preliminary results indicate that the presence of a semiconductor polymer (PAni) recovering the ceramic particles, make the poling process easier and less time consuming. Also, it is possible to observe that there is a great potential to use such type of composite as sensor for structure health monitoring.

Análise microestrutural e propriedades mecânicas do aço DP 600

Seeking to meet the requirements: relatively low cost of materials and wide applicability in the automotive industry. The best option was the steel Dual Phase (DP), because that is lighter, have high formability, meet the cost requirements and applicability, steel Dual Phase (DP) came to meet these requirements with its two-phase microstructure, ferrite and martensite microstructure who claim to respect and mechanical properties. In this context, the aim of this study was to correlate the microstructure revealed in metallography to the mechanical properties observed in hardness and tensile tests. The microstructure is revealed by etching in 2% nital and then captured images of the sample were processed in ImageJ software to aid in determining the volume fraction of the phases present. Therefore, the mechanical properties were evaluated with respect to volume fraction of the steel layers and analyzed DP 600 together with the mechanical properties obtained by Rockwell hardness test and tensile test. With the values of the mechanical properties calculated and tested, it was possible to describe the method of metallography, as the attack phase and counts, so that it can use this relationship tested/calculated property as a qualitative analytical tool. The method used for the correlation between the microstructure and mechanical properties confirmed the importance of the phases present in the Dual Phase steel to obtain the desired mechanical properties in the application of the steel

Fios ortodônticos superelásticos e sua aplicabilidade na clínica ortodôntica: revisão da literatura

During clinical routine, the orthodontist uses several materials, which include metallic alloys in the form of metallic wires. However, it is necessary that the professional has some knowledge of the properties of those wires. Different types of wires are commercially available: stainless steel wires, chrome-cobalt wires, nickel-titanium wires and beta-titanium wires. Among the nickel-titanium wires, there are three subdivisions: a conventional alloy and two superelastic alloys. The superelasticity, associated to the effect of form memory, is a property used in orthodontics to initiate the dental movement in the first phase of the orthodontic treatment. This property is considered to be biologically compatible with the effective dental movement. These wires are available at the market in different transformation temperatures, and they offer the best adaptation in the groove of the bracket, simplicity and a faster treatment. However, they present little formability, and they don’t accept solder. They are also more onerous than other wires. Moreover, the low rigidity of these wires doesn’t allow them to be used for the retraction of the anterior teeth or closing of spaces. Therefore, the coherent use of superelastic orthodontic wires is recommended, accompanied by a detailed diagnosis and planning, so the result will be an efficient orthodontic correction, accomplished in a shorter period of time.

Analysis of a Non-Traditional Micro Tube Hydroforming Process

As the demand for miniature products and components continues to increase, the need for manufacturing processes to provide these products and components has also increased. To meet this need, successful macroscale processes are being scaled down and applied at the microscale. Unfortunately, many challenges have been experienced when directly scaling down macro processes. Initially, frictional effects were believed to be the largest challenge encountered. However, in recent studies it has been found that the greatest challenge encountered has been with size effects. Size effect is a broad term that largely refers to the thickness of the material being formed and how this thickness directly affects the product dimensions and manufacturability. At the microscale, the thickness becomes critical due to the reduced number of grains. When surface contact between the forming tools and the material blanks occur at the macroscale, there is enough material (hundreds of layers of material grains) across the blank thickness to compensate for material flow and the effect of grain orientation. At the microscale, there may be under 10 grains across the blank thickness. With a decreased amount of grains across the thickness, the influence of the grain size, shape and orientation is significant. Any material defects (either natural occurring or ones that occur as a result of the material preparation) have a significant role in altering the forming potential. To date, various micro metal forming and micro materials testing equipment setups have been constructed at the Michigan Tech lab. Initially, the research focus was to create a micro deep drawing setup to potentially build micro sensor encapsulation housings. The research focus shifted to micro metal materials testing equipment setups. These include the construction and testing of the following setups: a micro mechanical bulge test, a micro sheet tension test (testing micro tensile bars), a micro strain analysis (with the use of optical lithography and chemical etching) and a micro sheet hydroforming bulge test. Recently, the focus has shifted to study a micro tube hydroforming process. The intent is to target fuel cells, medical, and sensor encapsulation applications. While the tube hydroforming process is widely understood at the macroscale, the microscale process also offers some significant challenges in terms of size effects. Current work is being conducted in applying direct current to enhance micro tube hydroforming formability. Initially, adding direct current to various metal forming operations has shown some phenomenal results. The focus of current research is to determine the validity of this process.