Dry grinding technology for automotive gears manufacturing: process modeling and optimization

The following thesis focused on the dry grinding process modelling and optimization for automotive gears production. A FEM model was implemented with the aim at predicting process temperatures and preventing grinding thermal defects on the material surface. In particular, the model was conceived to facilitate the choice of the grinding parameters during the design and the execution of the dry-hard finishing process developed and patented by the company Samputensili Machine Tools (EMAG Group) on automotive gears. The proposed model allows to analyse the influence of the technological parameters, comprising the grinding wheel specifications. Automotive gears finished by dry-hard finishing process are supposed to reach the same quality target of the gears finished through the conventional wet grinding process with the advantage of reducing production costs and environmental pollution. But, the grinding process allows very high values of specific pressure and heat absorbed by the material, therefore, removing the lubricant increases the risk of thermal defects occurrence. An incorrect design of the process parameters set could cause grinding burns, which affect the mechanical performance of the ground component inevitably. Therefore, a modelling phase of the process could allow to enhance the mechanical characteristics of the components and avoid waste during production. A hierarchical FEM model was implemented to predict dry grinding temperatures and was represented by the interconnection of a microscopic and a macroscopic approach. A microscopic single grain grinding model was linked to a macroscopic thermal model to predict the dry grinding process temperatures and so to forecast the thermal cycle effect caused by the process parameters and the grinding wheel specification choice. Good agreement between the model and the experiments was achieved making the dry-hard finishing an efficient and reliable technology to implement in the gears automotive industry.

Exact and heuristic algorithms for the integrated planning of multi-energy systems

The aim of this thesis is to present exact and heuristic algorithms for the integrated planning of multi-energy systems. The idea is to disaggregate the energy system, starting first with its core the Central Energy System, and then to proceed towards the Decentral part. Therefore, a mathematical model for the generation expansion operations to optimize the performance of a Central Energy System system is first proposed. To ensure that the proposed generation operations are compatible with the network, some extensions of the existing network are considered as well. All these decisions are evaluated both from an economic viewpoint and from an environmental perspective, as specific constraints related to greenhouse gases emissions are imposed in the formulation. Then, the thesis presents an optimization model for solar organic Rankine cycle in the context of transactive energy trading. In this study, the impact that this technology can have on the peer-to-peer trading application in renewable based community microgrids is inspected. Here the consumer becomes a prosumer and engages actively in virtual trading with other prosumers at the distribution system level. Moreover, there is an investigation of how different technological parameters of the solar Organic Rankine Cycle may affect the final solution. Finally, the thesis introduces a tactical optimization model for the maintenance operations’ scheduling phase of a Combined Heat and Power plant. Specifically, two types of cleaning operations are considered, i.e., online cleaning and offline cleaning. Furthermore, a piecewise linear representation of the electric efficiency variation curve is included. Given the challenge of solving the tactical management model, a heuristic algorithm is proposed. The heuristic works by solving the daily operational production scheduling problem, based on the final consumer’s demand and on the electricity prices. The aggregate information from the operational problem is used to derive maintenance decisions at a tactical level.

Study of the antioxidant fraction in edible olive oils obtained from different technological systems and parameters

Questo lavoro di tesi è stato suddiviso in tre parti. L’argomento principale è stato lo “Studio della componente antiossidante di oli ottenuti da olive mediante l’utilizzo di diversi sistemi e parametri tecnologici”. E’ ben noto come la qualità ossidativa di un olio di oliva dipenda oltre che dalla sua composizione in acidi grassi, dalla presenza di composti caratterizzati da un elevata attività antiossidante, ovvero le sostanze fenoliche. I composti fenolici contribuiscono quindi in maniera preponderante alla shelf life dell’olio extravergine di oliva. Inoltre sono state riscontrate delle forti correlazione tra alcune di queste sostanze e gli attributi sensoriali positivi di amaro e piccante. E’ poi da sottolineare come il potere antiossidante dei composti fenolici degli oli vergini di oliva, sia stato negli ultimi anni oggetto di considerevole interesse, poiché correlato alla protezione da alcune patologie come ad esempio quelle vascolari, degenerative e tumorali. Il contenuto delle sostanze fenoliche negli oli di oliva dipende da diversi fattori: cultivar, metodo di coltivazione, grado di maturazione delle olive e ovviamente dalle operazioni tecnologiche poiché possono variare il quantitativo di questi composti estratto. Alla luce di quanto appena detto abbiamo valutato l’influenza dei fattori agronomici (metodi di agricoltura biologica, integrata e convenzionale) e tecnologici (riduzione della temperatura della materia prima, aggiunta di coadiuvanti in fase di frangitura e di gramolatura, confronto tra tre oli extravergini di oliva ottenuti mediante diversi sistemi tecnologici) sul contenuto in composti fenolici di oli edibili ottenuti da olive (paper 1-3-4). Oltre alle sostanze fenoliche, negli oli di oliva sono presenti altri composti caratterizzati da proprietà chimiche e nutrizionali, tra questi vi sono i fitosteroli, ovvero gli steroli tipici del mondo vegetale, che rappresentano la frazione dell’insaponificabile quantitativamente più importante dopo gli idrocarburi. La composizione quali-quantitativa degli steroli di un olio di oliva è una delle caratteristiche analitiche più importanti nella valutazione della sua genuinità; infatti la frazione sterolica è significativamente diversa in funzione dell’origine botanica e perciò viene utilizzata per distinguere tra di loro gli oli e le loro miscele. Il principale sterolo nell’olio di oliva è il β- sitosterolo, la presenza di questo composto in quantità inferiore al 90% è un indice approssimativo dell’aggiunta di un qualsiasi altro olio. Il β-sitosterolo è una sostanza importante dal punto di vista della salute, poiché si oppone all’assorbimento del colesterolo. Mentre in letteratura si trovano numerosi lavori relativi al potere antiossidante di una serie di composti presenti nell’olio vergine di oliva (i già citati polifenoli, ma anche carotenoidi e tocoferoli) e ricerche che dimostrano invece come altri composti possano promuovere l’ossidazione dei lipidi, per quanto riguarda il potere antiossidante degli steroli e dei 4- metilsteroli, vi sono ancora poche informazioni. Per questo è stata da noi valutata la composizione sterolica in oli extravergini di oliva ottenuti con diverse tecnologie di estrazione e l’influenza di questa sostanza sulla loro stabilità ossidativa (paper 2). E’ stato recentemente riportato in letteratura come lipidi cellulari evidenziati attraverso la spettroscopia di risonanza nucleare magnetica (NMR) rivestano una importanza strategica da un punto di vista funzionale e metabolico. Questi lipidi, da un lato un lato sono stati associati allo sviluppo di cellule neoplastiche maligne e alla morte cellulare, dall’altro sono risultati anche messaggeri di processi benigni quali l’attivazione e la proliferazione di un normale processo di crescita cellulare. Nell’ambito di questa ricerca è nata una collaborazione tra il Dipartimento di Biochimica “G. Moruzzi” ed il Dipartimento di Scienze degli Alimenti dell’Università di Bologna. Infatti, il gruppo di lipochimica del Dipartimento di Scienze degli Alimenti, a cui fa capo il Prof. Giovanni Lercker, da sempre si occupa dello studio delle frazioni lipidiche, mediante le principali tecniche cromatografiche. L’obiettivo di questa collaborazione è stato quello di caratterizzare la componente lipidica totale estratta dai tessuti renali umani sani e neoplastici, mediante l’utilizzo combinato di diverse tecniche analitiche: la risonanza magnetica nucleare (1H e 13C RMN), la cromatografia su strato sottile (TLC), la cromatografia liquida ad alta prestazione (HPLC) e la gas cromatografia (GC) (paper 5-6-7)

Impact of guar and xanthan gums on proofing and calorimetric parameters of frozen bread dough

The influence of guar and xanthan gum and their combined use on dough proofing rate and its calorimetric properties was investigated. Fusion enthalpy, which is related to the amount of frozen water, was influenced by frozen dough formulation and storage time; specifically gum addition reduced the fusion enthalpy in comparison to control formulation, 76.9 J/g for formulation with both gums and 81.2 J/g for control, at 28th day. Other calorimetric parameters, such as T(g) and freezable water amount, were also influenced by frozen storage time. For all formulations, proofing rate of dough after freezing, frozen storage time and thawing, decreased in comparison to non-frozen dough, indicating that the freezing process itself was more detrimental to the proofing rate than storage time. For all formulations, the mean value of proofing rate was 2.97 +/- 0.24 cm(3) min(-1) per 100 g of non-frozen dough and 2.22 +/- 0.12 cm(3) min(-1) per 100 g of frozen dough. Also the proofing rate of non-frozen dough with xanthan gum decreased significantly in relation to dough without gums and dough with only guar gum. Optical microscopy analyses showed that the gas cell production after frozen storage period was reduced, which is in agreement with the proofing rate results. (C) 2008 Elsevier Ltd. All rights reserved.

Random regression models to estimate test-day milk yield genetic parameters Holstein cows in Southeastern Brazil

A total of 152,145 weekly test-day milk yield records from 7317 first lactations of Holstein cows distributed in 93 herds in southeastern Brazil were analyzed. Test-day milk yields were classified into 44 weekly classes of DIM. The contemporary groups were defined as herd-year-week of test-day. The model included direct additive genetic, permanent environmental and residual effects as random and fixed effects of contemporary group and age of cow at calving as covariable, linear and quadratic effects. Mean trends were modeled by a cubic regression on orthogonal polynomials of DIM. Additive genetic and permanent environmental random effects were estimated by random regression on orthogonal Legendre polynomials. Residual variances were modeled using third to seventh-order variance functions or a step function with 1, 6,13,17 and 44 variance classes. Results from Akaike`s and Schwarz`s Bayesian information criterion suggested that a model considering a 7th-order Legendre polynomial for additive effect, a 12th-order polynomial for permanent environment effect and a step function with 6 classes for residual variances, fitted best. However, a parsimonious model, with a 6th-order Legendre polynomial for additive effects and a 7th-order polynomial for permanent environmental effects, yielded very similar genetic parameter estimates. (C) 2008 Elsevier B.V. All rights reserved.

X ray densitometry applied to technological evaluation of MDF panels of eucalyptus

MDF panels from eucalyptus wood fibers were manufactured in laboratory and industrial production and had their apparent density profile determined by X-ray densitometry. The MDF panels apparent density parameters (maximum density of the superior and inferior faces; medium and minimum density) were determined and compared. The results indicated that the density values of the MDF panels made in the laboratory and in industrial line did not show significant statistical differences, indicating the similarities in the pressing phase of the fibers of both kinds. However, for MDF panels of laboratory and production line, the values of maximum, mean and minimum densities showed statistically significant correlations. The determination of the density profile for MDF panels by X-ray densitometry is important for the evaluation of pressing phase and other variables of the industrial process of production, as well for the determination of the technological properties.

Basic density and pulp yield relationship with some chemical parameters in eucalyptus trees

The objective of this work was to evaluate the use of basic density and pulp yield correlations with some chemical parameters, in order to differentiate an homogeneous eucalyptus tree population, in terms of its potential for pulp production or some other technological applications. Basic density and kraft pulp yield were determined for 120 Eucalyptus globulus trees, and the values were plotted as frequency distributions. Homogenized samples from the first and fourth density quartiles and first and fourth yield quartiles were submitted to total phenols, total sugars and methoxyl group analysis. Syringyl/guaiacyl (S/G) and syringaldehyde/vanillin (S/V) ratios were determined on the kraft lignins from wood of the same quartiles. The results show the similarity between samples from high density and low yield quartiles, both with lower S/G (3.88-4.12) and S/V (3.99-4.09) ratios and higher total phenols (13.3-14.3 g gallic acid kg-1 ). Woods from the high yield quartile are statistically distinguished from all the others because of their higher S/G (5.15) and S/V (4.98) ratios and lower total phenols (8.7 g gallic acid kg-1 ). Methoxyl group and total sugars parameters are more adequate to distinguish wood samples with lower density.

Influence of process parameters on part quality and mechanical properties for DMLS and SLM with iron-based materials

Rapid manufacturing is an advanced manufacturing technology based on layer-by-layer manufacturing to produce a part. This paper presents experimental work carried out to investigate the effects of scan speed, layer thickness, and building direction on the following part features: dimensional error, surface roughness, and mechanical properties for DMLS with DS H20 powder and SLM with CL 20 powder (1.4404/AISI 316L). Findings were evaluated using ANOVA analysis. According to the experimental results, build direction has a significant effect on part quality, in terms of dimensional error and surface roughness. For the SLM process, the build direction has no influence on mechanical properties. Results of this research support industry estimating part quality and mechanical properties before the production of parts with additive manufacturing, using iron-based powders

On the effects of welding parameters on weld quality of plasma arc keyhole welding of structural steels

The possibility and the usefulness of applying plasma keyhole welding to structural steels with different compositions and material thicknesses, and in various welding positions has been examinated. Single pass butt welding with I groove in flat, horizontal vertical and vertical positions and root welding with V , Y and U grooves of thick plate material in flat position have been studied and the welds with high quality has been obtained. The technological conditions for successful welding are presented. The single and interactive effects of welding parameters on weld quality, especially on surface weld defects, geometrical form errors, internal defects and mechanical properties (strength, ductility, impact toughness, hardness and bendability) of weld joint, are presented. Welding parameter combinations providing the best quality welds are also presented.

Technological development of 40mg furosemide tablets: equivalence and bioavaibility study in dogs

Furosemide (40mg) was administered to 20 street dogs, 10 males and 10 females, in two different pharmaceutical forms: (1) compressed furosemide 40mg formulated at the Federal University of Pernambuco (UFPE-tablet), and (2) a commercial formulation with equal bioequivalence produced by the Laboratory for Pharmaceutical Technology of Pernambuco State (LAFEPE), the LAFEPE-furosemide. The study aimed to evaluate the kinetics of dissolution of the UFPE-tablet in order to analyze the behavior of bioavailability of the best formulation for veterinary use. The plasmatic concentrations of furosemide for the determination of parameters of pharmacological kinetics were analyzed by high-performance liquid chromatographic method (HPLC). The in vitro study accomplished through physiochemical analyses demonstrated that the formulas of the furosemide tablets attained the pharmaceutical requirements in agreement with USP 23 and the Brazilian Pharmacopoeia. The evaluation accomplished in dogs with UFPE-tablets given in only dose demonstrated uniformity in blood levels indicating stability in maintenance of the pharmaceutical formulation and efficiency in absorption of the active compound. These values are not significantly different in relation to the 5% confidence limit. Regarding maximum concentration (Tmax) time and global bioavaibility assessed by AUC means, there were no considerable differences as well. UFPE-furosemide displayed 743.492µg/mL.h as AUC average value whereas LAFEPE-furosemide had an average of 537.284µg/mL.h.

Use of colour parameters for roasted coffee assessment

Fast and non-destructive indicators were evaluated as tools to measure the technological quality of Arabica and Robusta coffee. Accordingly, considering the roasting intensity in highly valuable commercial samples, volume, mass, apparent density, moisture, total ash, ash insoluble in hydrochloric acid, and ether extract were characterized. The chromatic parameters L*, C*, Hº were measured using illuminants D65 and C. It was found that in roasted coffee beans, the parameters L*, C*, Hº, and coordinate b* had an antagonist interaction due to an increase in the roasting intensity, whereas after milling, only L* and Hº decreased progressively. Considering that the parameters L* and Hº followed similar patterns using both illuminants, D65 and C, it can be concluded that they are appropriate to evaluate coffee colour changes during roasting, enabling a relationship with coffee quality.

Effect of adding unconventional raw materials on the technological properties of rice fresh pasta

The aim of this study was to develop fettuccini type rice fresh pasta by cold extrusion. To produce the pasta, a 2² Central Composite Rotational Design was used, in which the effects of the addition of pre-gelatinized rice flour - PGRF (0-60%) and modified egg albumin - MEA (0-10%) were studied. The dependent variables were the results of the cooking test and of the instrumental texture. The optimum cooking time for all of the formulations of rice fresh pasta was 3 minutes. MEA had a greater effect on increasing the weight of the pasta when compared to that of PGRF. It was found that with the addition of PGRF increase in loss of solids in cooking water, whereas MEA exerted the opposite effect on this parameter. Moreover, the maximum value of MEA (10%) had an optimum effect on pasta firmness, while PGRF had a negative effect on this parameter. The maximum values of PGRF and MEA reduced the stickiness of the pasta. Based on these results and on the parameters considered as most important, the rice pasta with the best technological characteristics was that with the maximum levels of MEA (10%) and no addition of PGRF (0%). This product was submitted to sensory and microbiological analyses, with good results.

Influence of the addition of lupine protein isolate on the protein and technological characteristics of dough and fresh bread with added Brea Gum

The effect of protein lupine isolate (LI) and addition of brea gum (BG) on a basic bread formulation is described. The major objective of this research was to evaluate the influence of the addition of LI on the quality and quantity of the proteins of fresh bread with BG. Protein quality was determinate by the Chemical Score method corrected for protein digestibility (CSCD%). The bread dough characteristics were determined by farinograph and alveograph. Fresh bread characterization was performed by measuring the physical parameters and evaluating the crumb structure. The effect of LI and BG on available lysine, the loss of available lysine ratio, and the chemical composition of the breads were also determined. The addition of LI on the bread formulation improved the protein content and the CSCD% of lysine. The dough with LI was less resistant to prolonged kneading and less manageable. With BG addition, the dough became stickier. The quality of fresh bread was affected by the addition of LI: the fresh bread had lower specific volume and more heterogeneous crumbs than that of the control group. The addition of BG did not influence the quality of the bread made with the mixed flour, but it had a positive effect on the loss of available lysine.

Effects of orange by-product fiber incorporation on the functional and technological properties of pasta

AbstractThe incorporation of fiber into products consumed every day by the general population is important and viable. The aim of the present work was to evaluate the impact of incorporating orange juice industry dietary fiber byproducts in fettuccini of fresh pasta. Three different fiber concentrations were added to fresh pastas (25 g/kg, 50 g/kg and 75 g/kg). The results showed a significant increase in solid loss content when the incorporation of orange fiber was greater than 50 g/kg. This difference did not occur regarding weight increase values and color parameters. The pasta with 75 g/kg orange fiber can be considered a “high fiber” product, with the total dietary fiber content of the pasta increasing by 99% compared to control pasta. The carotenoid and phenolic contents of pasta increased significantly with the incorporation of fiber at 75 g/kg, but only the pasta formulation with 25 g/kg of orange fiber did not differ from control pasta in relation to all of the sensory attributes and presented an acceptance greater than 75%. The addition of orange fiber byproducts to pastas is an interesting alternative because fiber has a high nutritional value and an abundance of antioxidants.

Studies all transport and magnetic properties of nano particle doped MgB2 superconductor for technological applications

This thesis Entitled Studies on transport and magnetic properties of nano particle doped mgb2 superconductor for technological applications.The thesis ahead focuses on the establishment of enhanced superconducting properties in bulk MgB2 via nano particle doping and its conversion into mono/multifilamentary wires. Further, an attempt has also been made to develop prototypes of MgB2 coil and conduction cooled current lead for technological applications. The thesis is configured into 6 chapters. The opening chapter gives an idea on the phenomenon of superconductivity, the various types of superconductors and its applications in different fields. The second chapter is an introduction on MgB2 superconductor and its relevance which includes crystal and electronic structure, superconducting mechanism, basic superconducting properties along with its present international status. The third chapter provides details on the preparation and characterization techniques followed through out the study on MgB2. Fourth chapter discusses the effect of processing temperature and chemical doping using nano sized dopants on the superconducting properties of MgB2• Fifth chapter deals with the optimization of processing parameters and novel preparation techniques for wire fabrication. Sixth chapter furnishes the preparation of multifilamentary wires with various filament configurations, their electromechanical properties and it also incorporates the development of an MgB2 coil and a general purpose conduction cooled current lead.