Minimization of stock weight during close-die forging of a spindle

In this paper, Finite Element method and full-scale experiments have been used to study a hot forging method for fabri-cation of a spindle using reduced initial stock size. The forging sequence is carried out in two stages. In the first stage, the hot rolled cylindrical billet is pre-formed and pierced in a closed die using a spherical nosed punch to within 20 mm of its base. This process of piercing or impact extrusion leads to high strains within the work piece but requires high press loads. In the second stage, the resulting cylinder is placed in a die with a flange chamber and upset forged to form a flange. The stock mass is optimized for complete die filling. Process parameters such as effective strain distribution, material flow and forging load in different stages of the process are analyzed. It is concluded from the simulations that minor modifications of piercing punch geometry to reduce contact between the punch and emerging vertical walls of the cylinder appreciably reduces the piercing load. In the flange chamber, a die surfaces angle of 52° instead of 45° is pro-posed to ensure effective material flow and exert sufficient tool pressure to achieve complete cavity filling. In order to achieve better compression, it is also proposed to shorten both the length of the inserted punch and the die “tongues” by a few mm.

Determination of drawbead contacts with variable bead penetration

In stamping operations, the sliding of the sheet metal over the drawbeads is of great importance. The geometry of the drawbead and the degree of penetration both influence material flow and alter the frictional effects between the work and the tool. The effect of drawbead penetration over drawbeads has been studied using the Drawbead Simulator (DBS) test. The contact phenomenon between the sheet and drawbeads was analysed by examining deformed samples with an image fitting technique. The results were compared with an FE simulation and with an approximate geometric analysis. The results give a useful relationship between the rates of change of the contact angle with increasing bead penetration.

Kanban devs modelling, simulation and verification

Kanban Control Systems (KCS) have become a widely accepted form of inventory and production control. The creation of realistic Discrete Events Simulation (DES) models of KCS require specification of both information and material flow. There are several commercially available simulation packages that are able to model these systems although the use of an application specific modelling language provides means for rapid model development. A new Kanban specific simulation language as well as a high-speed execution engine is verified in this paper through the simulation of a single stage single part type production line. A single stage single part KCS is modelled with exhaustive enumeration of the decision variables of container sizes and number of Kanbans. Several performance measures were used; 95% Confidence Interval (CI) of container Flow Time (FT), mean line throughput as well as the Coefficient of Variance (CV) of FT and Cycle Time were used to determine the robustness of the control system.

Application of the strain localization CAFE model to investigate extrusion with various die shapes

Multi scale CAFE model for the prediction of initiation and propagation of the micro shear bands and shear bands in metallic materials subjected to plastic deformation is presented. The CAFE approach is the combination of the Cellular Automata (CA) and the Finite Element (FE) methods. The application of the developed CAFE model to analyze material flow during extrusion is the objective of the present work. The proposed CAFE approach is applied in this work to simulation of the extrusion with flat face and convex dies and to investigate differences in the material flow. The initial FE meshes with the set of the CA point are generated for the numerical tests and the results of the metal flow predicted by the CAFE method are presented in the paper.

Effect of tool speeds during friction stir lap welding on mode of fracture and fracture strength of Al 6060-T5 joints

Friction stir lap welding (FSLW) of an age hardened Al alloy and evaluations of how FS speeds affected hooking and how hooking and softening due to FS affected fracture strength of the lap welds have been conducted. It was found that increasing rotation speed and reducing welding speed (v) increased the stir zone size (AB-SZ) and also hook size (h), although a maximum value of h (hMax) reached. The features of hooks for the observed - AB-SZ-h relationships are presented and explained. It was found that when h increased to a value of ~ 0.9 mm (for the 3 mm alloy sheets), it started to invoke a significant effect on reducing fracture strength. Factors such as FS softening and insufficient joining, limited the fracture strength of the lap welds for small h values and these are presented and discussed.

Fracture strengths of Mg alloy AZ31B-H24 friction stir lap welds

The effects of selected friction stir lap welding parameters on fracture strength of Mg alloy AZ31B-H24 welds have been studied. Rotation speed has been found to affect significantly the flow related hook size formation. Furthermore, fracture strength decreased almost linearly with hook size. A small amount of softening was detected in fracture location that was outside the nugget zone and thus this softening may only adversely affect the fracture strength slightly. Finally, simulation results are presented to show the uneven stress distribution in a lap geometry which together with the relative brittleness of the stir material must be the cause to have significantly reduced the fracture strength.

Finite element analysis of an axi-symmetric forward spiral extrusion of Mg-1.75Mn alloy

A potential severe plastic deformation process known as axi-symmetrical forward spiral extrusion (AFSE) has been studied numerically and experimentally. The process is based on the extrusion of cylindrical samples through a die with engraved spiral grooves in a near zero shape change manner. The process was simulated using a three dimensional finite element (FE) model that has been developed using commercial software, ABAQUS. In order to verify the finite element results, hot rolled and annealed samples of the alloy were experimentally processed by AFSE. The required extrusion forces during the process were estimated using the FE model and compared with the experimental values. The reasonable agreement between the FE results and experimental data verified the accuracy of the FE model. The numerical results indicate the linear strain distribution in the AFSE sample is only valid for a core concentric while the strain distribution in the vicinity of the grooves is non axi-symmetric. The FE simulation results from this research allows a better understanding of AFSE kinematics especially near the grooves, the required extrusion force and the resultant induced strain distribution in the sample. To compare the mechanical properties of the Mg-1.75Mn alloy before and after the process, a micro shear punch test was used. The tests were performed on samples undergoing one and four passes of AFSE. After four passes of AFSE, it was observed that the average shear strength of the alloy has improved by about 21%. The developedfinite element model enables tool design and material flow simulation during the process.

Análise e melhoria de layout de processo na indústria de beneficiamento de couro

A aplicação de técnicas de estudo de sistemas em ambientes industriais com grande concorrência, é cada vez mais significativa devido às modificações e flexibilidade de produção exigidas. A aplicação de técnicas de análise e ajustes de layouts são algumas destas técnicas que podem trazer resultados competitivos positivos. O presente trabalho descreve os tipos de layouts existentes, com suas aplicações, vantagens e desvantagens com a finalidade de analisar e propor melhorias em layouts de processo na indústria coureira. O trabalho enfoca ainda os principais pontos a serem considerados quando da criação de um novo layout ou do ajuste e/ou melhoria de um existente. Para tal, foi realizado um estudo de caso utilizando a técnica de Melhoria de Layout de Silveira (1998), com a aplicação do Planejamento Sistemático de Layout em um layout de processo do setor da Secagem, característico em uma indústria beneficiadora de couro. Os resultados obtidos traduzem o re-arranjo de seus postos de trabalho com redução do fluxo de material de acordo com a aproximação de postos com relações de afinidade. Essa alteração possibilitou uma melhor organização espacial dos postos de trabalho e um melhor controle da produção, através da separação natural dos lotes. A metodologia adotada pode ser utilizada como ferramenta de melhoria nos demais setores, tanto da própria empresa, como do mercado coureiro em geral.

Uso de técnicas de otimização baseadas em derivadas como suporte do planejamento operacional de redes de distribuição de energia elétrica

The usual programs for load flow calculation were in general developped aiming the simulation of electric energy transmission, subtransmission and distribution systems. However, the mathematical methods and algorithms used by the formulations were based, in majority, just on the characteristics of the transmittion systems, which were the main concern focus of engineers and researchers. Though, the physical characteristics of these systems are quite different from the distribution ones. In the transmission systems, the voltage levels are high and the lines are generally very long. These aspects contribute the capacitive and inductive effects that appear in the system to have a considerable influence in the values of the interest quantities, reason why they should be taken into consideration. Still in the transmission systems, the loads have a macro nature, as for example, cities, neiborhoods, or big industries. These loads are, generally, practically balanced, what reduces the necessity of utilization of three-phase methodology for the load flow calculation. Distribution systems, on the other hand, present different characteristics: the voltage levels are small in comparison to the transmission ones. This almost annul the capacitive effects of the lines. The loads are, in this case, transformers, in whose secondaries are connected small consumers, in a sort of times, mono-phase ones, so that the probability of finding an unbalanced circuit is high. This way, the utilization of three-phase methodologies assumes an important dimension. Besides, equipments like voltage regulators, that use simultaneously the concepts of phase and line voltage in their functioning, need a three-phase methodology, in order to allow the simulation of their real behavior. For the exposed reasons, initially was developped, in the scope of this work, a method for three-phase load flow calculation in order to simulate the steady-state behaviour of distribution systems. Aiming to achieve this goal, the Power Summation Algorithm was used, as a base for developing the three phase method. This algorithm was already widely tested and approved by researchers and engineers in the simulation of radial electric energy distribution systems, mainly for single-phase representation. By our formulation, lines are modeled in three-phase circuits, considering the magnetic coupling between the phases; but the earth effect is considered through the Carson reduction. It s important to point out that, in spite of the loads being normally connected to the transformer s secondaries, was considered the hypothesis of existence of star or delta loads connected to the primary circuit. To perform the simulation of voltage regulators, a new model was utilized, allowing the simulation of various types of configurations, according to their real functioning. Finally, was considered the possibility of representation of switches with current measuring in various points of the feeder. The loads are adjusted during the iteractive process, in order to match the current in each switch, converging to the measured value specified by the input data. In a second stage of the work, sensibility parameters were derived taking as base the described load flow, with the objective of suporting further optimization processes. This parameters are found by calculating of the partial derivatives of a variable in respect to another, in general, voltages, losses and reactive powers. After describing the calculation of the sensibility parameters, the Gradient Method was presented, using these parameters to optimize an objective function, that will be defined for each type of study. The first one refers to the reduction of technical losses in a medium voltage feeder, through the installation of capacitor banks; the second one refers to the problem of correction of voltage profile, through the instalation of capacitor banks or voltage regulators. In case of the losses reduction will be considered, as objective function, the sum of the losses in all the parts of the system. To the correction of the voltage profile, the objective function will be the sum of the square voltage deviations in each node, in respect to the rated voltage. In the end of the work, results of application of the described methods in some feeders are presented, aiming to give insight about their performance and acuity

Dedução de Funções de Alívio para Priorização de Variantes de Chaveamento Adequadas à Eliminação de Sobrecargas

Eventually, violations of voltage limits at buses or admissible loadings of transmission lines and/or power transformers may occur by the power system operation. If violations are detected in the supervision process, corrective measures may be carried out in order to eliminate them or to reduce their intensity. Loading restriction is an extreme solution and should only be adopted as the last control action. Previous researches have shown that it is possible to control constraints in electrical systems by changing the network topology, using the technique named Corrective Switching, which requires no additional costs. In previous works, the proposed calculations for verifying the ability of a switching variant in eliminating an overload in a specific branch were based on network reduction or heuristic analysis. The purpose of this work is to develop analytical derivation of linear equations to estimate current changes in a specific branch (due to switching measures) by means of few calculations. For bus-bar coupling, derivations will be based on short-circuit theory and Relief Function methodology. For bus-bar splitting, a Relief Function will be derived based on a technique of equivalent circuit. Although systems of linear equations are used to substantiate deductions, its formal solution for each variant, in real time does not become necessary. A priority list of promising variants is then assigned for final check by an exact load flow calculation and a transient analysis using ATP Alternative Transient Program. At last, results obtained by simulation in networks with different features will be presented

Uso de técnicas de otimização baseadas em derivadas como suporte do planejamento operacional de redes de distribuição de energia elétrica

The usual programs for load flow calculation were in general developped aiming the simulation of electric energy transmission, subtransmission and distribution systems. However, the mathematical methods and algorithms used by the formulations were based, in majority, just on the characteristics of the transmittion systems, which were the main concern focus of engineers and researchers. Though, the physical characteristics of these systems are quite different from the distribution ones. In the transmission systems, the voltage levels are high and the lines are generally very long. These aspects contribute the capacitive and inductive effects that appear in the system to have a considerable influence in the values of the interest quantities, reason why they should be taken into consideration. Still in the transmission systems, the loads have a macro nature, as for example, cities, neiborhoods, or big industries. These loads are, generally, practically balanced, what reduces the necessity of utilization of three-phase methodology for the load flow calculation. Distribution systems, on the other hand, present different characteristics: the voltage levels are small in comparison to the transmission ones. This almost annul the capacitive effects of the lines. The loads are, in this case, transformers, in whose secondaries are connected small consumers, in a sort of times, mono-phase ones, so that the probability of finding an unbalanced circuit is high. This way, the utilization of three-phase methodologies assumes an important dimension. Besides, equipments like voltage regulators, that use simultaneously the concepts of phase and line voltage in their functioning, need a three-phase methodology, in order to allow the simulation of their real behavior. For the exposed reasons, initially was developped, in the scope of this work, a method for three-phase load flow calculation in order to simulate the steady-state behaviour of distribution systems. Aiming to achieve this goal, the Power Summation Algorithm was used, as a base for developping the three phase method. This algorithm was already widely tested and approved by researchers and engineers in the simulation of radial electric energy distribution systems, mainly for single-phase representation. By our formulation, lines are modeled in three-phase circuits, considering the magnetic coupling between the phases; but the earth effect is considered through the Carson reduction. Its important to point out that, in spite of the loads being normally connected to the transformers secondaries, was considered the hypothesis of existence of star or delta loads connected to the primary circuit. To perform the simulation of voltage regulators, a new model was utilized, allowing the simulation of various types of configurations, according to their real functioning. Finally, was considered the possibility of representation of switches with current measuring in various points of the feeder. The loads are adjusted during the iteractive process, in order to match the current in each switch, converging to the measured value specified by the input data. In a second stage of the work, sensibility parameters were derived taking as base the described load flow, with the objective of suporting further optimization processes. This parameters are found by calculating of the partial derivatives of a variable in respect to another, in general, voltages, losses and reactive powers. After describing the calculation of the sensibility parameters, the Gradient Method was presented, using these parameters to optimize an objective function, that will be defined for each type of study. The first one refers to the reduction of technical losses in a medium voltage feeder, through the installation of capacitor banks; the second one refers to the problem of correction of voltage profile, through the instalation of capacitor banks or voltage regulators. In case of the losses reduction will be considered, as objective function, the sum of the losses in all the parts of the system. To the correction of the voltage profile, the objective function will be the sum of the square voltage deviations in each node, in respect to the rated voltage. In the end of the work, results of application of the described methods in some feeders are presented, aiming to give insight about their performance and acuity

Implementação de um algoritmo para a análise de curtos-circuitos de alta impedância baseado no fluxo de carga soma de potências

This work has as main objective to show all the particularities regarding the Three-phase Power Summation Method, used for load flow calculation, in what it says respect to the influence of the magnetic coupling among the phases, as well as to the losses presented in all the existent transformers in the feeder to be analyzed. Besides, its application is detailed in the study of the short-circuits, that happen in the presence of high impedance values, which possess a problem, that is its difficult detection and consequent elimination on the part of common devices of protection. That happens due to the characteristic presented by the current of short¬ circuit, in being generally of the same order of greatness that the load currents. Results of simulations accomplished in several situations will be shown, objectifying a complete analysis of the behavior of the proposed method in several types of short-circuits. Confront of the results obtained by the method with results of another works will be presented to verify its effectiveness

Desempenho da colhedora de milho Penha CLM-350: parte II - sistemas de debulhamento e limpeza

Com a finalidade de quantificar o desempenho dos sistemas de debulhamento e limpeza da colhedora Penha CLM-350,, estudou-se as perdas percentuais era grão de milho, ocorridos na saída de palhas, bem como a porcentagem de impurezas, presente no milho ensacado. Tomando-se como 100% os grãos de milho colhidos pelo sistema espigador, determinou-se o valor percentual perdido pelos sistemas de debulhamento e limpeza, bem como a porcentagem de impurezas presente nos grãos de milho ensacado, nos diversos tratamentos estudados. O teor médio de umidade foi de 15,78% (b.u.). Os tratamentos correspondentes ao sistema de debulhamento e limpeza são as velocidades periféricas do debulhador ou as rotações do aspirador em faces da configuração geométrica da máquina. Os resultados obtidos foram estudados através da análise de variância, empregando-se os testes F, aos níveis de 1% e 5% de probabilidade e o teste Tukey, para a comparação estatística entre as médias. A análise estatística para verificar a influência da rotação do aspirador, era relação a porcentagem de grãos de milho perdidos na saída de palhas, mostrou diferenças altamente significativas, podendo-se admitir uma relação direta entre os dois parâmetros nas condições do ensaio. Com relação a rotação do aspirador e a porcentagem de impurezas, presentes nos grãos de milho ensacados, os testes das médias revelaram significância entre os tratamento D (1241,7 rpm) e E (820 rpm) sendo que este último apresentou a maior média. Uma análise mais acurada dos resultados sugere que a porcentagem de impurezas, estaria mais na dependência das relações de fluxo através da colhedora, do que propriamente do regime do aspirador.

Desempenho da colhedora de milho Penha CLM-350: parte III - danos mecânicos

Cm vistas a estudar o efeito do sistema de debulhamento na qualidade dos grãos de milho, realizou-se o presente trabalho, onde foram estudados os danos mecânicos sofridos pelos grãos, bem como os danos mecânicos invisíveis, evidenciados pelos testes de germinação. Nos diversos tratamentos estudados, determinou-se a porcentagem de umidade presente nos grãos de milho. Definiu-se a velocidade periférica do debulhador, pelo diâmetro (300 mm) do mesmo e as rotações, para os diversos tratamentos. O delineamento experimental foi de blocos ao acaso com 5 tratamentos e 6 repetições onde foram estudados os valores percentuais de grãos inteiros e quebrados, os teores de umidade correspondentes e os valores de germinação através da análise de variância. Empregou-se o teste F aos níveis de 1% e 5% de probabilidade e o teste Tukey para comparação entre as médias. da análise pode-se concluir que em relação ao teor de umidade dos grãos, os tratamentos não diferiram estatisticamente.

Sistemas de adubação e consórcio de culturas intercalares e seus efeitos nas variáveis de colheita da cultura do milho

A colheita é a operação final de campo do processo produtivo, e por isso os fatores que interferem na mesma devem ser observados e avaliados atentamente para reduzir ao mínimo as perdas nessa etapa. O objetivo deste trabalho foi avaliar a influência dos sistemas de adubação (em pré-semeadura e na semeadura) e dos consórcios de culturas intercalares (milho+mucuna-cinza-anã, milho+guandu-anão e milho+lablab) nas variáveis de colheita da cultura do milho em sistema plantio direto. O experimento foi realizado na UNESP de Jaboticabal - SP, no período de safra normal, utilizando-se do delineamento em blocos ao acaso, no esquema fatorial (2 x 3), com quatro repetições. Os componentes avaliados na colheita foram: diâmetro do colmo, altura de inserção da primeira espiga, altura da planta, número de espigas por planta, índice de espiga, número de fileiras na espiga, biomassa seca da palhada no solo, estande final, produtividade de grãos, fluxos de grãos, de palha e de sabugo e perdas na colheita. Os resultados demonstraram que o diâmetro do colmo, a altura de inserção da primeira espiga e a altura de plantas apresentaram maiores valores para o sistema de adubação na semeadura. O número de fileiras, espigas viáveis, índice de espiga, estande final, biomassa seca da palhada, produtividade, fluxos de palha, de sabugo, de grãos e as perdas na colheita não foram afetados pelos sistemas de adubação e os consórcios.