Modelling of porosity defects in high pressure die casting with a neural network

High Pressure Die Casting (HPDC) is a complex process that results in casting defects if configured improperly. However, finding out the optimal configuration is a non-trivial task as eliminating one of the casting defects (for example, porosity) can result in occurrence of other casting defects. The industry generally tries to eliminate the defects by trial and error which is an expensive and error -prone process. This paper aims to improve current modelling and understanding of defects formation in HPDC machines. We have conducted conventional die casting tests with a neural network model of HPDC machine and compared the obtained results with the current understanding of formation of porosity. While most of our findings correspond well to established knowledge in the field, some of our findings are in conflict with the previous studies of die casting.

Contact pressure and wear in sheet metal forming - an FEM analysis

Wear is the principal cause of tool failure in most sheet metal forming processes. It is well known that the contact pressure between the blank and the tool has a large influence on the wear of the tool, and hence the tool life. This investigation utilises the finite element method to analyse the contact pressure distribution over the die radius for a particular deep drawing process. Furthermore, the evolution of the predicted contact pressure distribution throughout the entire stroke of the punch is also examined. It was found that the majority of the process shows a steady state pressure distribution, with two characteristic peaks over the die radius, at the beginning and end of the sheet contact area. Interestingly, the initial transient contact pressure response showed extremely high localised peak pressures; more than twice that of the steady state peaks. Results are compared to wear reported in the literature, during similar experimental deep drawing processes. Finally, the significance and effect of the results on wear and wear-testing techniques are discussed.

Modeling of contact pressure in sheet metal forming

For a given sheet metal forming process, an accurate determination of the contact pressure distribution experienced is an essential step towards the estimation of tool life. This investigation utilizes finite element (FE) analysis to determine the evolution and distribution of contact pressure over the die radius, throughout the duration of a channel forming process. It was found that a typical two-peak steady-state contact pressure response exists for the majority of the process. However, this was preceded by a transient  response, which produced extremely large and localized contact pressures. Notably, it was found that the peak transient contact pressure was more than double the steady-state peak. These contact pressure results may have a significant influence on the tool wear response and therefore impact current wear testing and prediction techniques. Hence, an investigation into the validity of the predicted contact pressure was conducted.

Simulation of contact pressure in sheet metal trimming/blanking process

In the car body stamping process, trim/blank die cutting edges are subjected to very high tribological loads that result in loss of tool material from both the punch and die cutting edges. According to Archard’s wear model, normal contact force and sliding distance directly affects the wear. Therefore, knowledge of the acting forces on local contact areas has a pivotal role towards the prediction of tool wear. This paper presents a finite element modelling approach to determining the contact pressure distribution on the tool cutting edges during a trimming/blanking process. Characteristic areas on sheared edge profile, variation of punch force and high contact pressures affected areas have also been analysed.

Contact pressure evolution and its relation to wear in sheet metal forming

For a given sheet metal forming process, an accurate determination of the contact pressure distribution is an essential step towards the estimation of tool life. This investigation utilizes finite element (FE) analysis to model and explain the evolution and distribution of contact pressure over the die radius, throughout the duration of a channel forming process. It was found that a typical two-peak steady-state contact pressure response exists for the majority of the process. However, this was preceded by an initial transient response, characterized by extremely large and localized contact pressures, which were more than double the magnitude of the steady-state peak pressure. The validity of the predicted contact pressure behavior was assessed via detailed numerical analysis and by examining the wear response of an experimental stamping operation. The experimental results revealed that the high contact pressure zones of the transient response corresponded to a severe galling wear mechanism. Therefore, the transient response may be of primary significance to the tool wear response; thus questioning the applicability of traditional bending-under-tension wear tests for sheet metal stamping processes. Finally, a parametric study was conducted, examining the influence of the major process parameters on the steady-state and peak transient contact pressures, using the developed FE model. It was found that the bend ratio and the blank material ultimate tensile strength had the most influence on the peak contact pressures. The main process-related parameters, friction coefficient and blank holder force, were found to have only a minor influence.

Contact pressure prediction in sheet metal forming using finite element analysis

Tool wear has become a significant issue associated with the forming of high strength sheet steels in the automotive industry. In order to combat this problem, recent research has been devoted to utilizing the contact results obtained from current sheet metal forming software predictions, in order to develop/apply tool wear models or tool material selection criteria for use in the stamping plant. This investigation aims to determine whether a specialized sheet metal forming software package can correctly capture the complex contact conditions that occur during a typical sheet metal stamping process. The contact pressure at the die radius was compared to results obtained using a general-purpose finite element software package, for a simple channel-forming process. Although some qualitative similarities between the two predictions were observed, it was found that significant differences in the magnitude and distribution of the contact pressure exists. The reasons for the discrepancies in results are discussed with respect to the simplifications and assumptions adopted in the finite element model definitions, and with regards to other results available in the literature.

Numerical investigation of high and low pressure tube hydroforming

Hydroforming is one option to reduce vehicle weight while increasing component stiffness and rigidity. This typically involves using a fluid to form a component with high internal pressure. Tube hydroforming has gained increasing interest in the automotive and aerospace industries because of its many advantages such as part consolidation, good quality of the formed part etc. The main advantage is that the uniform pressure can be transferred to whole part at the same time. In low pressure hydroforming, the internal pressure is significantly and the hydroformed section length of line stays almost the same as the circumference of the blank tube. This paper details the comparison between high and low pressure hydroforming. It is shown that the internal pressure and holding force required for low pressure hydroforming process is much less than that of high pressure. Also stress and thickness distribution are more uniform and the process is highly suitable for the forming of advanced high strength steels.

Contact pressure evolution at the die radius in sheet metal stamping

The contact conditions at the die radius are of primary importance to the wear response for many sheet metal forming processes. In particular, a detailed understanding of the contact pressure at the wearing interface is essential for the application of representative wear tests, the use of wear resistant materials and coatings, the development of suitable wear models, and for the ultimate goal of predicting tool life. However, there is a lack of information concerning the time-dependant nature of the contact pressure response in sheet metal stamping. This work provides a qualitative description of the evolution and distribution of contact pressure at the die radius for a typical channel forming process. Through an analysis of the deformation conditions, contact phenomena and underlying mechanics, it was identified that three distinct phases exist. Significantly, the initial and intermediate stages resulted in severe and localised contact conditions, with contact pressures significantly greater than the blank material yield strength. The final phase corresponds to a larger contact area, with steady and smaller contact pressures. The proposed contact pressure behaviour was compared to other results available in the literature and also discussed with respect to tool wear.

Heavy metal accumulation in soils at three field sites subject to effluent irrigation

Three field sites were chosen to study the environmental assimilative capacity of heavy metals in soil. These sites were the Werribee Farm and the Myome Farm in Australia and Shenyang Zhangshi Irrigation Area in China. The Werribee Farm and the Shenyang Zhangshi Irrigation Area received sewage treatment and application on land for a long time. The Myome farm is an experimental site in which investigations on land application of municipal wastewater on water repellent soils is currently being trailed. Heavy metal contamination, in particular Cr, Cu and Zn, in the Land Filtration soil of Werribee Farm was widespread. More than a century of sewage irrigation has occurred in the Werribee Farm. The temporal distribution pattern of heavy metals (Cd, Cr, Cu, Ni, Pb and Zn) in the soil at this site follow an exponential trend with time and the spatial distribution pattern of accumulation of heavy metals in different paddocks correlates with the number of years of sewage irrigation at that site in the Farm. Extensive sewage irrigation at Shenyang Zhangshi Irrigation Area resulted in significant Cd pollution in soil-plant (rice) system and poses a significant threat to the health of local people. Even after eight years since cessation of sewage irrigation, the bioavailable fractions of Cd in the soil as analyzed by sequential extraction techniques were very high thus illustrating long-term persistence. The simultaneous competitive adsorption of metals in water repellent soils (at Myome Farm in South Australia) was studied. In the competitive situation, Cr, Pb and Cu are the heavy metal cations more strongly adsorbed by the soil, whereas Cd, Ni and Zn are the least adsorbed. The increase in Freundlich adsorption capacity by clay amendment suggested that clayed soils are capable sorption of higher heavy metal loadings compared to the non-clayed water repellent soil, which is more vulnerable to heavy metal inputs. A simple model of environmental assimilative capacity is proposed. The results of comparison of the three field sites shows that the Werribee Farm has a higher environmental assimilative capacity of heavy metals in soil than the soils at Shenyang Zhangshi Irrigation Area and Myome Farm, however heavy metal contamination at Werribee Farm is still a concern. The model of environmental assimilative capacity of heavy metals in soil is an effective tool to assist management of effluent applied land irrigation systems and can be used to better design environmental engineering systems.

FEA comparison of high and low pressure tube hydroforming of TRIP steel

The increasing application of hydroforming for the production of automotive lightweight components is mainly due to the attainable advantages regarding part properties and improving technology of the forming equipment. However, the high pressure requirements during hydroforming decreases the costs benefit and make the part expensive. Another requirement of automotive industries is weight reduction and better crash performance. Thereby steel industries developed advanced high strength steels which have high strength, good formability and better crash performance. Even though the thickness of the sheet to form the component is reduced, the pressure requirement to form the part during expansion is still high during high pressure hydroforming. This paper details the comparison between high and low pressure tube hydroforming for the square cross-section geometry. It is determined that the internal pressure and die closing force required for low pressure tube hydroforming process is much less than that of high pressure tube hydroforming process. The stress and thickness distribution of the part during tube crushing were critically analysed. Further, the stress distribution and forming mode were studied in this paper. Also friction effect on both processes was discussed.

Coming soon (to a theatre near you) : the temporality of global film distribution to Australia

This article explores the changing contexts of international film exhibition in Australia over a 20-year period (1989–2009) by examining in some empirical detail Australia’s position in the global flow of films during this time. It argues that, at the most abstract level, distributors are engaged in the management and mediation of time and space in the field of global communications. It is proposed that distributors, through the organisation of temporal differentiation, are explicitly active in the creation of both cultural and commodity value. This is particularly apparent as film distributors explore and engage new methodologies of film release, which emphasise overlapping, intersecting and contradictory temporalities in the cinema experience.

Burial depth distribution of fennel pondweed tubers (Potamogeton pectinatus) in relation to foraging by Bewick's swans

Deep burial in the sediment of tubers of fennel pondweed (Potamogeton pectinatus) has been explained in terms of avoidance by escape against consumption by Bewick's swans (Cygnus columbianus bewickii) in autumn. We therefore expected changes in foraging pressure to ultimately result in a change in the tuber distribution across sediment depth. A trade-off underlies this idea: deep tubers are less accessible to swans but must be larger to meet the higher energy demands of sprouting in spring. To test this prediction, we compared tuber burial depth over a gradient of foraging pressure both across space and across time. Tuber samples were obtained after aboveground plant senescence but before arrival of Bewick's swans. First, we compared the current tuber bank depth profile in a shallow lake with high foraging pressure, the Lauwersmeer, with that in two wetlands with moderate and low foraging pressure. Second, we compared the current tuber burial in the Lauwersmeer with that in the early 1980s when exploitation by swans had just started there. In accordance with our hypothesis, we found significantly deeper burial of tubers under high consumption risk compared to low consumption risk, both when comparing sites and comparing time periods. Since tubers in effect only survive to the next spring, the observed differences in burial depth among sites and over time cannot be a direct result of tuber losses due to consumption by swans. Rather, these observations suggest adaptive responses in tuber burial related to foraging pressure from Bewick's swans in the recent past. We thus propose that fennel pondweed exhibits flexible avoidance by escape, of a kind rarely described for plants, where both phenotypic plasticity and genotype sorting may contribute to the observed differences in tuber burial.

Measurement of aqueous film thickness between charged mercury and mica surfaces : a direct experimental probe of the Poisson-Boltzmann distribution

A stable aqueous electrolyte film is formed between a mercury drop and a flat mica surface due to electrical double-layer repulsion when a negative potential is applied to the mercury. Film thickness has been measured as a function of applied potential while keeping the film pressure constant. By making measurements in this way, it is possible to map the data directly according to the Poisson-Boltzmann equation. An excellent fit to the data is obtained, providing direct evidence for this classical equation and its use as the basis of the Gouy-Chapman model of the diffuse double layer in electrolyte solutions.

Analysis of the current distribution in an aluminum electrolysis cell with copper collector-bar cathode assembly

Understanding the magneto-hydrodynamic forces generated due to the external magnetic field and current density distribution within the cell (current in cell linings) is important in the optimization of cell dynamics. It is well documented that these factors play a crucial role in establishing the metal-pad stability of the cell. Conventional cells use the cathode-collector-bar assembly to carry the current through molten aluminium, the cathode and the steel collector-bar to nearest external bus. The electrical conductivity of the steel is so poor relative to the molten aluminium that the outer third of the collector bar carries the maximum load, which in turn increases the horizontal components of the current within the cell. Previous studies have modelled improvement in the cell instability through external magnetic compensation by redistributing current in the cathode busbar. Very little to date has been published on work to improve the current distribution within the cell. In this work, the current distribution in an aluminium electrolysis cell with copper collector-bar was predicted using finite element modelling. A 2D cross-section of a commercial cell was used under steady conditions of electrical fields in anode, electrolyte, molten aluminium and copper cathode-assembly. Different shapes and sizes of the cathode assembly are also considered to optimise the distribution of current throughout the cathode lining. The findings indicated that the copper-bar of similar size to steel could save voltage up to 150 mV. There is a reduction of more than 70% in peak current density value due to the copper inserts. The predicted trends of current distribution show a good agreement with previously published data.

Mitochondrial DNA analysis of field populations of Helicoverpa armigera (Lepidoptera : Noctuidae) and of its relationship to H. zea

Background
Helicoverpa armigera and H. zea are amongst the most significant polyphagous pest lepidopteran species in the Old and New Worlds respectively. Separation of H. armigera and H. zea is difficult and is usually only achieved through morphological differences in the genitalia. They are capable of interbreeding to produce fertile offspring. The single species status of H. armigera has been doubted, due to its wide distribution and plant host range across the Old World. This study explores the global genetic diversity of H. armigera and its evolutionary relationship to H zea.

Results
We obtained partial (511 bp) mitochondrial DNA (mtDNA) Cytochrome Oxidase-I (COI) sequences for 249 individuals of H. armigera sampled from Australia, Burkina Faso, Uganda, China, India and Pakistan which were associated with various host plants. Single nucleotide polymorphisms (SNPs) within the partial COI gene differentiated H. armigera populations into 33 mtDNA haplotypes. Shared haplotypes between continents, low F-statistic values and low nucleotide diversity between countries (0.0017 – 0.0038) suggests high mobility in this pest. Phylogenetic analysis of four major Helicoverpa pest species indicates that H. punctigera is basal to H. assulta, which is in turn basal to H. armigera and H. zea. Samples from North and South America suggest that H. zea is also a single species across its distribution. Our data reveal short genetic distances between H. armigera and H. zea which seem to have been established via a founder event from H. armigera stock at around 1.5 million years ago.

Conclusion
Our mitochondrial DNA sequence data supports the single species status of H. armigera across Africa, Asia and Australia. The evidence for inter-continental gene flow observed in this study is consistent with published evidence of the capacity of this species to migrate over long distances. The finding of high genetic similarity between Old World H. armigera and New World H. zea emphasises the need to consider work on both pests when building pest management strategies for either.