Multiphysics simulation of microwave curing in micro-electronics packaging applications

Purpose – This paper aims to present an open-ended microwave curing system for microelectronics components and a numerical analysis framework for virtual testing and prototyping of the system, enabling design of physical prototypes to be optimized, expediting the development process. Design/methodology/approach – An open-ended microwave oven system able to enhance the cure process for thermosetting polymer materials utilised in microelectronics applications is presented. The system is designed to be mounted on a precision placement machine enabling curing of individual components on a circuit board. The design of the system allows the heating pattern and heating rate to be carefully controlled optimising cure rate and cure quality. A multi-physics analysis approach has been adopted to form a numerical model capable of capturing the complex coupling that exists between physical processes. Electromagnetic analysis has been performed using a Yee finite-difference time-domain scheme, while an unstructured finite volume method has been utilized to perform thermophysical analysis. The two solvers are coupled using a sampling-based cross-mapping algorithm. Findings – The numerical results obtained demonstrate that the numerical model is able to obtain solutions for distribution of temperature, rate of cure, degree of cure and thermally induced stresses within an idealised polymer load heated by the proposed microwave system. Research limitations/implications – The work is limited by the absence of experimentally derived material property data and comparative experimental results. However, the model demonstrates that the proposed microwave system would seem to be a feasible method of expediting the cure rate of polymer materials. Originality/value – The findings of this paper will help to provide an understanding of the behaviour of thermosetting polymer materials during microwave cure processing.

Dynamic melting model for small samples in cold crucible

Purpose – A small size cold crucible offers possibilities for melting various electrically conducting materials with a minimal wall contact. Such small samples can be used for express contamination analysis, preparing limited amounts of reactive alloys or experimental material analyses. Aims to present a model to follow the melting process. Design/methodology/approach – The presents a numerical model in which different types of axisymmetric coil configurations are analysed. Findings – The presented numerical model permits dynamically to follow the melting process, the high-frequency magnetic field distribution change, the free surface and the melting front evolution, and the associated turbulent fluid dynamics. The partially solidified skin on the contact to the cold crucible walls and bottom is dynamically predicted. The segmented crucible shape is either cylindrical, hemispherical or arbitrary shaped. Originality/value – The model presented within the paper permits the analysis of melting times, melt shapes, electrical efficiency and particle tracks.

Performance measurement and benchmarking of a major innovation programme

Purpose: The purpose of this paper is to describe the problems encountered and the solutions developed when using benchmarking and key performance indicators (KPIs) to monitor a major UK social house building innovation (change) programme. The innovation programme sought improvements to both the quality of the house product and the procurement process. Design/methodology/approach: Benchmarking and KPIs were used to quantify performance and in-depth case studies to identify underlying cause and effect relationships within the innovation programme. Findings: The inherent competition between consortium members; the complexity of the relationship between the consortium and its strategic partner; the lack of an authoritative management control structure; and the rapidly changing nature of the UK social housing market all proved problematic to the development of a reliable and robust monitoring system. These problems were overcome by the development of multi-dimensional benchmarking model that balanced the needs and aspirations of the individual organisations with the broader objectives of the consortium. Research limitations/implications: Whilst the research methodology provides insight into the factors that affected the performance of a major innovation programme its findings may not be representative of all projects. Practical implications: The lessons learnt should assist those developing benchmarking models for multi-client consortia. Originality/value: The work reported in this paper describes an inclusive approach to benchmarking in which a multiple client group and their strategic partner sought to work together for shared gain. Very few papers have addressed this issue.

Applying a QSPR correlation to the prediction of surface tensions of ionic liquids

Ionic liquids (ILs) have attracted large amount of interest due to their unique properties. Although large effort has been focused on the investigation of their potential application, characterization of ILs properties and structure–property relationships of ILs are poorly understood. Computer aided molecular design (CAMD) of ionic liquids (ILs) can only be carried if predictive computational methods for the ILs properties are available. The limited availability of experimental data and their quality have been preventing the development of such tools. Based on experimental surface tension data collected from the literature and measured at our laboratory, it is here shown how a quantitative structure–property relationship (QSPR) correlation for parachors can be used along with an estimation method for the densities to predict the surface tensions of ILs. It is shown that a good agreement with literature data is obtained. For circa 40 ionic liquids studied a mean percent deviation (MPD) of 5.75% with a maximum deviation inferior to 16% was observed. A correlation of the surface tensions with the molecular volumes of the ILs was developed for estimation of the surface tensions at room temperature. It is shown that it can describe the experimental data available within a 4.5% deviation. The correlations here developed can thus be used to evaluate the surface tension of ILs for use in process design or in the CAMD of new ionic liquids.

Use of Digital Manufacturing to Improve Management Learning in Aerospace Assembly

The primary goal of this work is to quantify any bene?ts that the use of digital manufacturing methods can offer when used upstream from production, for manufacturing process design, and tool development. Learning at this stage of product development is referred to as management learning. Animated build simulations have been used to develop build procedures and tooling for a panel assembly for the new Bombardier CRJ1000 (Canadair Regional Jet, 100 seat). When the jig format was developed, its simulated performance was compared to that of current CRJ700/900 panel builds to identify and quantify any improvements in terms of tooling cost and panel build time. When comparing like-for-like functions between existing CRJ700/900 (Canadair Regional Jet, 70/90 seat) and the
CRJ1000 tooling, it was predicted that the digitally assisted improvements had brought about a 4.9% reduction in jig cost. An evaluation of the build process for the CRJ1000 uplock panel predicted a 5.2% reduction in the assembly time. In addition to the improvement of existing tooling functions, new jig functionality was added so that both the drilling and riveting functions could be carried out in a single jig for the new RJ1000 panel.

Mass transfer correlation in flotation of palm oil by colloidal gas aphrons

Colloidal gas aphrons (CGAs) are micron-sized bubbles, which are produced by stirring a dilute surfactant solution at a high speed. In this work, CGAs have been used to clarify oily wastewater by flotation technique. The CGAs sparging rate was a critical factor that governed the efficiency of the process. A model for the determination of the mass transfer coefficient is also developed for the purpose of process design.

Thermophysical Properties of Amino Acid-Based Ionic Liquids

Ionic liquids (ILs) having either cations or anions derived from naturally occurring amino acids have been synthesized and characterized as amino acid-based ionic liquids (AAILs) In this work, the experimental measurements of the temperature dependence or density. viscosity, heat capacity, and thermal conductivity of several AAILs, namely, tributylmethylammonium serinate ([N-444][Ser], tributylmethylammonium taurmate ([N-444][Tau]) tributylmethylammonium lysinate a [N-444][ Lys]), tributylmethylammonium threonate ([N-444][Thr]), tetrabutylphosphonium serinate ([P-4444][Ser]), tetrabutylphosphonium taurmate ([P-4444][Tau]), tetrabutylphosphonium lysinate ([P-4444][Lys]), tetrabutylphosphonium threonate P-4444 Thr tetrabutylphosphonium prolinate P-4444 ((Pro(), tetrabutylphosphonium valinate ([P-4444][Val]), and tetrabutylphosphonium cysteinate ([P-4444][Cys]), are presented The influence of cations and anions on studied properties is discussed. On the basis of experimental data. the QSPR (quantitative structure property relationship) correlations and group contribution methods for thermophysical properties of AAILs have been developed, which form the basis for the development of the computer-aided molecular design (CAMD) of AAILs It has also been demonstrated that that the predictive data obtained by con elation methods ale in good agreement with the experimental data The correlations developed, herein. can thus be used to evaluate the studied thermophysical properties of AAILs for use in process design or in the CAMD of new AAILs

A virtual inspection framework for precision manufacturing of aerofoil components

The finite element method plays an extremely important role in forging process design as it provides a valid means to quantify forging errors and thereby govern die shape modification to improve the dimensional accuracy of the component. However, this dependency on process simulation could raise significant problems and present a major drawback if the finite element simulation results were inaccurate. This paper presents a novel approach to assess the dimensional accuracy and shape quality of aeroengine blades formed from finite element hot-forging simulation. The proposed virtual inspection system uses conventional algorithms adopted by modern coordinate measurement processes as well as the latest free-form surface evaluation techniques to provide a robust framework for virtual forging error assessment. Established techniques for the physical registration of real components have been adapted to localise virtual models in relation to a nominal Design Coordinate System. Blades are then automatically analysed using a series of intelligent routines to generate measurement data and compute dimensional errors. The results of a comparison study indicate that the virtual inspection results and actual coordinate measurement data are highly comparable, validating the approach as an effective and accurate means to quantify forging error in a virtual environment. Consequently, this provides adequate justification for the implementation of the virtual inspection system in the virtual process design, modelling and validation of forged aeroengine blades in industry.

Biomass-derived Oxymethylene Ethers as Diesel Additives: A Thermodynamic Analysis

Conversion of biomass for production of liquid fuels can help in reducing the greenhouse gas (GHG) emissions which are predominantly generated by combustion of fossil fuels. Adding oxymethylene ethers (OMEs) in conventional diesel fuel has the potential to reduce soot formation during the combustion in a diesel engine. OMEs are downstream products of syngas, which can be generated by the gasification of biomass. In this research, a thermodynamic analysis has been conducted through development of data intensive process models of all the unit operations involved in production of OMEs from biomass. Based on the developed model, the key process parameters affecting the OMEs production including equivalence ratio, H2/CO ratio, and extra water flow rate were identified. This was followed by development of an optimal process design for high OMEs production. It was found that for a fluidized bed gasifier with heat capacity of 28 MW, the conditions for highest OMEs production are at an air amount of 317 tonne/day, at H2/CO ratio of 2.1, and without extra water injection. At this level, the total OMEs production is 55 tonne/day (13 tonne/day OME3 and 9 tonne/day OME4). This model would further be used in a techno-economic assessment study of the whole biomass conversion chain to determine the most attractive pathways.

Caracterização do “warpage” e sua variabilidade no processo produtivo de encapsulamento de circuitos integrados

Nos últimos anos a indústria de semicondutores, nomeadamente a produção de memórias, tem sofrido uma grande evolução. A necessidade de baixar custos de produção, assim como de produzir sistemas mais complexos e com maior capacidade, levou à criação da tecnologia WLP (Wafer Level Packaging). Esta tecnologia permite a produção de sistemas mais pequenos, simplificar o fluxo do processo e providenciar uma redução significativa do custo final do produto. A WLP é uma tecnologia de encapsulamento de circuitos integrados quando ainda fazem parte de wafers (bolachas de silício), em contraste com o método tradicional em que os sistemas são individualizados previamente antes de serem encapsulados. Com o desenvolvimento desta tecnologia, surgiu a necessidade de melhor compreender o comportamento mecânico do mold compound (MC - polímero encapsulante) mais especificamente do warpage (empeno) de wafers moldadas. O warpage é uma característica deste produto e deve-se à diferença do coeficiente de expansão térmica entre o silício e o mold compound. Este problema é observável no produto através do arqueamento das wafers moldadas. O warpage de wafers moldadas tem grande impacto na manufatura. Dependendo da quantidade e orientação do warpage, o transporte, manipulação, bem como, a processamento das wafers podem tornar-se complicados ou mesmo impossíveis, o que se traduz numa redução de volume de produção e diminuição da qualidade do produto. Esta dissertação foi desenvolvida na Nanium S.A., empresa portuguesa líder mundial na tecnologia de WLP em wafers de 300mm e aborda a utilização da metodologia Taguchi, no estudo da variabilidade do processo de debond para o produto X. A escolha do processo e produto baseou-se numa análise estatística da variação e do impacto do warpage ao longo doprocesso produtivo. A metodologia Taguchi é uma metodologia de controlo de qualidade e permite uma aproximação sistemática num dado processo, combinando gráficos de controlo, controlo do processo/produto, e desenho do processo para alcançar um processo robusto. Os resultados deste método e a sua correta implementação permitem obter poupanças significativas nos processos com um impacto financeiro significativo. A realização deste projeto permitiu estudar e quantificar o warpage ao longo da linha de produção e minorar o impacto desta característica no processo de debond. Este projecto permitiu ainda a discussão e o alinhamento entre as diferentes áreas de produção no que toca ao controlo e a melhoria de processos. Conseguiu–se demonstrar que o método Taguchi é um método eficiente no que toca ao estudo da variabilidade de um processo e otimização de parâmetros. A sua aplicação ao processo de debond permitiu melhorar ou a fiabilidade do processo em termos de garantia da qualidade do produto, como ao nível do aumento de produção.

Microbial Treatment Of Rubber Latex Centrifugation Effluent

Many of the existing methods for the treatment of rubber latex centrifugation eflluent are not only unsatisfactory in their efliciency to effect near perfect treatment in bringing down the COD to optimum level, but also time consuming and need a large landspace. As the rate of effluent generation is extremely high (20 litres for kilogram of rubber) there is a need for development of efficient system,capable of rapid reduction of COD and BOD. Though the organic load of the rubber efiluent is very high, it does not contain much processed chemicals and therefore it can be considered as a ‘biological eflluent’. Further, the ratio of the Chemical Oxygen Demand to Biological Oxygen Demand (COD/BOD) of this effluent remain almost as a constant value. According to Montgomery (1967), estimation of BOD is not ideally suited for studies on process design, treatability, control of treatment plants, setting standards for treated effluents and assessing the effect of polluting discharges on the oxygen resources of receiving waters. Hence in the present study COD was measured to determine the impact of treatment system on the effluent. In the present study, attempts were made to evaluate the efficiencies of certain methods such as packed bed reactor using immobilized microbial cells, rotating biological contactor (RBC) and activated sludge process, for rapid and efficient treatment of natural rubber latex centrifugation effluent. In addition, studies were also carn'ed out to develop a suitable bioprocess for the coagulation of skim latex, as an alternative to the presently used acid coagulation process towards reducing the pollution load, besides recovering quality rubber

MitWirkung - Zukunft gestalten

Die Diskussion in den Planungswissenschaften beschreibt den Paradigmenwechsel vom so genannten DEAD-Model (Decide-Announce-Defend) zum Tripple-D-Model (Dialogue-Decide-Deliver) und beschäftigt sich intensiv mit dem Thema Governance. Komplexe Planungsaufgaben brauchen eine Vielfalt an Lösungsideen unterschiedlicher gesellschaftlicher Gruppen. Planung verfolgt u. a. die Umsetzung der Ziele einer nachhaltigen Entwicklung, die die Einbeziehung der Öffentlichkeit (Zivilgesellschaft, Unternehmen und Bürger) verlangt. Darüber hinaus wird eine Erweiterung der Perspektive über Verfahren und Steuerungsformen hinaus auf Akteure und Prozesse gefordert. Räumliche Entwicklungen sollen stärker im Zusammenhang mit Entscheidungsfindungsprozesse untersucht werden. Die Dissertation ergänzt eine wirkungsorientierte Perspektive, die Wirkungen, sowohl räumliche als auch soziale, in den Mittelpunkt der Betrachtung stellt. Sie stützt sich auf Beobachtungen, dass klassisches Projektmanagement für erfolgreiche Planungsprozesse nicht ausreicht, sondern zusätzlich Prozessmanagement braucht. Mit der Weiterentwicklung der partizipativen Planung, die zusätzlich in den Kontext gesellschaftlicher Lernprozesse und zukunftsfähiger Veränderungen gesellschaftlicher Bedingungen gestellt wird, ergänzt die Dissertation planungswissenschaftliche Theorien. Aus einem fachübergreifenden Blickwinkel wird die räumliche Planung in die Reihe von Management- und Organisationswissenschaften eingeordnet. Ausgehend von der Frage, welche räumlichen und sozialen Wirkungen durch Beteiligungsprozesse unter welchen Bedingungen erzielt werden, wurden Fallstudien aus der Wasserwirtschaft und ihre Prozessbiografien umfassend evaluiert. Als Evaluierungsmethode wurde ein von der EU-Kommission empfohlener Evaluierungsrahmen gewählt, der sowohl den Prozess selbst, seine Rahmenbedingungen und Durchführung, als auch Wirkungen analysiert und bewertet. Auf der Grundlage der Ergebnisse und theoretischer Erkenntnisse, vorrangig aus der Evaluationsforschung, wird ein umfassender Beteiligungsansatz konzipiert. Dabei handelt es sich um ein offenes Gerüst, in das sich bewährte und innovative Elemente strategisch gezielt integrieren lassen. Die Struktur verbindet verschiedene Beteiligungswerkzeuge unterschiedlicher Intensitäten und für unterschiedliche Zielgruppen zu einem Gesamtkonzept, mit dem Ziel, möglichst die gewünschten Wirkungen zu erreichen. Wesentlich an dem Ansatz ist, dass bereits das Prozessdesign unter Mitwirkung von Projektträgern, Beratern und Schlüsselakteuren erfolgt. Die partizipative Beteiligungsplanung bedeutet somit Klärung der Vorgehensweise und gleichzeitig Bewusstseins- und Kompetenzerweiterung der verantwortlichen Akteure. Im Ausblick werden künftige Forschungsaufgaben im Bereich der Mitwirkung in der räumlichen Planung formuliert und Handlungsmöglichkeiten aufgezeigt, um Partizipation als Teil planerischer „Alltagskultur“ weiterzuentwickeln. Dies erfolgt vor dem Hintergrund der Bedeutung von Partizipation und Bildung als Umsetzungsstrategie von Ideen der Landschaftsentwicklung und Nachhaltigkeit.

Aplicació d'algoritmes genètics en l'optimització dels processos de fabricació del paper

La creciente preocupación y concienciación de la sociedad respecto el medio ambiente, y en consecuencia la legislación y regulaciones generadas inducen a la modificación de los procesos productivos existentes en la industria química. Las configuraciones iniciales deben modificarse para conseguir una mayor integración de procesos. Para este fin se han creado y desarrollado diferentes metodologías que deben facilitar la tarea a los responsables del rediseño. El desarrollo de una metodología y herramientas complementarias es el principal objetivo de la investigación aquí presentada, especialmente centrada en el desarrollo y la aplicación de una metodología de optimización de procesos. Esta metodología de optimización se aplica sobre configuraciones de proceso existentes y pretende encontrar nuevas configuraciones viables según los objetivos de optimización fijados. La metodología tiene dos partes diferenciadas: la primera se basa en un simulador de procesos comercial y la segunda es la técnica de optimización propiamente dicha. La metodología se inicia con la elaboración de una simulación convenientemente validada que reproduzca el proceso existente, en este caso una papelera no integrada que produce papel estucado de calidad, para impresión. A continuación la técnica de optimización realiza una búsqueda dentro del dominio de los posibles resultados, en busca de los mejores resultados que satisfazcan plenamente los objetivos planteados. Dicha técnica de optimización está basada en los algoritmos genéticos como herramienta de búsqueda, junto a un subprograma basado en técnicas de programación matemática para el cálculo de resultados. Un número reducido de resultados son finalmente escogidos y utilizados para modificar la simulación existente fijando la redistribución de los flujos del proceso. Los resultados de la simulación del proceso determinan en último caso la viabilidad técnica de cada reconfiguración planteada. En el proceso de optimización, los objetivos están definidos en una función objetivo dentro de la técnica de optimización. Dicha función rige la búsqueda de resultados. La función objetivo puede ser individual o una combinación de objetivos. En el presente caso, la función persigue una minimización del consumo de agua y una minimización de la pérdida de materia prima. La optimización se realiza bajo restricciones para alcanzar este objetivo combinado en forma de una solución de compromiso. Producto de la aplicación de esta metodología se han obtenido resultados interesantes que significan una mejora del cierre de circuitos y un ahorro de materia prima, sin comprometer al mismo tiempo la operabilidad del proceso producto ni la calidad del papel.

The effect of skin passing on the material behavior of metal strip in pure bending and tension

The metal strip used in roll forming has often been preprocessed by (tension or roller) leveling or by skin-pass rolling, and as a consequence, may contain residual stresses. These stresses are not well observed by the tensile test, but could have a significant effect on the bending and springback behavior. With the advent of improved process design techniques for roll forming, including advanced finite element techniques, the need for precise material property data has become important. The major deformation mode of roll forming is that of bending combined with unloading and reverse bending, and hence property data derived from bend tests could be more relevant than that from tensile testing.

This work presents a numerical study on the effect of skin passing on the material behavior of stainless steel strip in pure bending and tension. A two dimensional (2-D) numerical model was developed using Abaqus Explicit to analyze the affect of skin passing on the residual stress profile across a section for various working conditions. The deformed meshes and their final stress fields were then imported as pre-defined fields into Abaqus Standard, and the post-skin passing material behavior in pure bending was determined. The results show that a residual stress profile is introduced into the steel strip during skin passing, and that its shape and stress level depend on the overall thickness reduction as well as the number of rolling passes used in the skin passing process. The material behavior in bending and the amount of springback changed significantly depending on the skin pass condition.

Review of approximate analyses of sheet forming processes

Approximate models are often used for the following purposes: in on-line control systems of metal forming processes where calculation speed is critical; to obtain quick, quantitative information on the magnitude of the main variables in the early stages of process design; to illustrate the role of the major variables in the process; as an initial check on numerical modelling; and as a basis for quick calculations on processes in teaching and training packages. The models often share many similarities; for example, an arbitrary geometric assumption of deformation giving a simplified strain distribution, simple material property descriptions - such as an elastic, perfectly plastic law - and mathematical short cuts such as a linear approximation of a polynomial expression. In many cases, the output differs significantly from experiment and performance or efficiency factors are developed by experience to tune the models. In recent years, analytical models have been widely used at Deakin University in the design of experiments and equipment and as a pre-cursor to more detailed numerical analyses. Examples that are reviewed in this paper include deformation of sandwich material having a weak, elastic core, load prediction in deep drawing, bending of strip (particularly of ageing steel where kinking may occur), process analysis of low-pressure hydroforming of tubing, analysis of the rejection rates in stamping, and the determination of constitutive models by an inverse method applied to bending tests.