Fusing data-mining and knowledge elicitation for the supervisory control of an aluminium plate mill

Knowledge-elicitation is a common technique used to produce rules about the operation of a plant from the knowledge that is available from human expertise. Similarly, data-mining is becoming a popular technique to extract rules from the data available from the operation of a plant. In the work reported here knowledge was required to enable the supervisory control of an aluminium hot strip mill by the determination of mill set-points. A method was developed to fuse knowledge-elicitation and data-mining to incorporate the best aspects of each technique, whilst avoiding known problems. Utilisation of the knowledge was through an expert system, which determined schedules of set-points and provided information to human operators. The results show that the method proposed in this paper was effective in producing rules for the on-line control of a complex industrial process.

Quantitative assessment of through-thickness crack size based on Lamb wave scattering in aluminium plates

The interaction of Lamb wave modes at varying frequencies with a through-thickness crack of different lengths in aluminium plates was analysed in terms of finite element method and experimental study. For oblique-wave incidence, both numerical and experimental results showed that the wave scattering from a crack leads to complicated transmission, reflection and diffraction accompanied by possible wave-mode conversion. A dual-PZT actuation scheme was therefore applied to generate the fundamental symmetrical mode (S0) with enhanced energy to facilitate the identification of crack-scattered wave components. The relationship between crack length and the reflection/transmission coefficient obtained with the aid of the Hilbert transform was established, through which the crack length was quantitatively evaluated. The effects of wavelength of Lamb waves and wave diffraction on the properties of the reflection and transmission coefficients were analysed.

Roll forming cryo-rolled nano-structured aluminium sheet

Commercial purity aluminium plate was reduced by rolling under nitrogen in 30 passes from an initial material thickness of 10 mm to a final thickness of 2 mm (80% reduction). Analysis of the microstructure showed that the material produced in this way had an ul-trafine grained microstructure. The sheet was roll formed at room temperature to a V-section using commercial roll forming equipment. Two sets of experiments were per-formed; one with a 15 mm radius in the base of the V and the other with a 5 mm radius. The performance in terms of final shape and springback is compared with the same part shape formed by V-die bending. The mechanical properties of the sheet were determined using the tensile test. It has been found that even if the total tensile elongation is close to zero and bending of the material is very limited, ultra-fine grained and low ductile sheet metals can be roll formed to simple section shapes.

Roll-formability of cryo-rolled ultrafine aluminium sheet

Ultrafine-grain aluminium sheet was produced by rolling at cryogenic (CR) and at room temperature (RTR). Commercial purity aluminium plate was reduced in 30 passes from an initial material thickness of 10 mm to a final thickness of 2 mm (80% reduction). Tensile stress and strength were significantly increased while total elongation was drastically reduced. It was found that despite the low tensile elongation both materials are able to accommodate high localised strains in the neck leading to a high reduction in area. The formability of the material was further investigated in bending operations. A minimum bending radius of 6 mm (CR) and 5 mm (RTR) was found and pure bending tests showed homogeneous forming behaviour for both materials. In V-die bending the cryo-rolled material showed strain localisations across the final radius and kinking of the sample. It has been found that even if the total elongation in tension is close to zero leading to early failure in V-die bending, ultra-fine grained and low ductile sheet metals can be roll formed to simple section shapes with small radii using commercial roll forming equipment.

Finite element analysis of warpage in laminated aluminium alloy plates for machining of primary aeronautic parts

The aim of this paper consists in presenting a method of simulating the warpage in 7xxx series aluminium alloy plates. To perform this simulation finite element software MSC.Patran and MSC.Marc were used. Another result of this analysis will be the influence on material residual stresses induced on the raw material during the rolling process upon the warpage of primary aeronautic parts, fabricated through machining (milling) at Embraer. The method used to determinate the aluminium plate residual stress was Layer Removal Test. The numerical algorithm Modified Flavenot Method was used to convert layer removal and beam deflection in stress level. With such information about the level and profile of residual stresses become possible, during the step that anticipate the manufacturing to incorporate these values in the finite-element approach for modelling warpage parts. Based on that warpage parameter surely the products are manufactured with low relative vulnerability propitiating competitiveness and price. © 2007 American Institute of Physics.

Spallation analysis with a closed trans-scale formulation damage evolution

A closed, trans-scale formulation of damage evolution based on the statistical microdamage mechanics is summarized in this paper. The dynamic function of damage bridges the mesoscopic and macroscopic evolution of damage. The spallation in an aluminium plate is studied with this formulation. It is found that the damage evolution is governed by several dimensionless parameters, i.e., imposed Deborah numbers De* and De, Mach number M and damage number S. In particular, the most critical mode of the macroscopic damage evolution, i.e., the damage localization, is deter-mined by Deborah number De+. Deborah number De* reflects the coupling and competition between the macroscopic loading and the microdamage growth. Therefore, our results reveal the multi-scale nature of spallation. In fact, the damage localization results from the nonlinearity of the microdamage growth. In addition, the dependence of the damage rate on imposed Deborah numbers De* and De, Mach number M and damage number S is discussed.

Scanning LDV for vibration measurement of filiform hairs in crickets in response to induced airflow - art. no. 63450E

Cercal hairs represent in cricket a wind sensitive escape system, able to detect the airflow generated from predating species. These sensors have been studied as a biomimetic concept to allow the development of MEMS for biomedical use. In particular, the behaviour of the hairs, including airflow response, resonant frequency and damping, has been investigated up to a frequency of 20 kHz. The microscopic nature of the hairs, the complex vibrations of excited hairs and the high damping of the system suggested that the use of Laser Doppler vibrometry could possibly improve the test performance. Two types of tests were performed: in the first case the hairs were indirectly excited using the signal obtained from a vibrating aluminium plate, whilst in the second case the hairs were directly excited using a white noise chirp. The results from the first experiment indicated that the hairs move in-phase with the exciting signal up to frequencies in the order of 10 kHz, responding to the vibration modes of the plate with a signal attenuation of 12 to 20 dB. The chirp experiment revealed the presence of rotational resonant modes at 6850 and 11300 Hz. No clear effect of hair length was perceivable on the vibration response of the filiform sensors. The obtained results proved promising to support the mechanical and vibration characterisation of the hairs and suggest that scanning Laser vibrometry can be used extensively on highly dampened biological materials.

Novo conceito de juntas adesivas utilizando laminados de fibras e metal

Devido às necessidades da indústria atual é cada vez mais importante a utilização de métodos de união de materiais distintos. A utilização de adesivos no processo de produção de materiais compósitos tem uma grande aplicação, uma vez que permite ligar os diferentes materiais e ainda reduzir significativamente o peso do conjunto. Este trabalho teve como principal objetivo aumentar a resistência à delaminação de materiais compósitos no sentido da espessura, concretamente dos plásticos reforçados com fibras de carbono (CFRP), através da utilização de placas da liga de alumínio 2024-T3. Este conceito é muito semelhante ao utilizado nos laminados por fibras e metal (LFM) para aumentar a sua resistência à delaminação. Pretendeu-se também a identificação da configuração da junta que apresenta melhores resultados, comparativamente à junta de referência composta apenas por CFRP. Inicialmente, produziram-se apenas juntas de CFRP que foram utilizadas como comparação com os laminados de fibras e metal. Com o objetivo de melhorar a adesão entre os CFRP e a liga de alumínio, foram realizados três tratamentos superficiais diferentes, nomeadamente a lixagem, a anodização e o ataque com ácido. Posteriormente, foram produzidas as juntas com as seguintes configurações: CFRP-AL-CFRP, CFRP-AL-CFRP-AL-CFRP e AL-CFRP-AL. A realização deste trabalho permitiu concluir que com a adição de placas de alumínio, se conseguiu um melhoramento da resistência à delaminação das fibras de carbono e ainda um aumento da resistência específica no sentido da sua espessura. A JSS com a configuração AL-CFRP-AL e com comprimento de sobreposição de 50 mm foi a configuração que apresentou uma força de rotura mais elevada, ou seja, uma maior resistência à delaminação, comparativamente à junta de referência e às restantes configurações em estudo. A falha coesiva verificada perto da interface da junta AL-CFRP-AL, pode ser devida ao elevado comprimento de sobreposição e às diferentes elasticidades do alumínio e do CFRP, o que naturalmente levou a elevadas tensões localizadas nas extremidades da junta. Os resultados demostraram que é possível aumentar a resistência transversal do compósito utilizando uma placa de alumínio.

Influence of surface texture and roughness parameters on friction and transfer layer formation during sliding of aluminium pin on steel plate

Surface texture of harder mating surfaces plays an important role during sliding against softer materials and hence the importance of characterizing the surfaces in terms of roughness parameters. In the present investigation, basic studies were conducted using inclined pin-on-plate sliding tester to understand the surface texture effect of hard surfaces on coefficient of friction and transfer layer formation. A tribological couple made of a super purity aluminium pin against steel plate was used in the tests. Two surface parameters of steel plates, namely roughness and texture, were varied in the tests. It was observed that the transfer layer formation and the coefficient of friction along with its two components, namely, the adhesion and plowing, are controlled by the surface texture and are independent of surface roughness (R-a). Among the various surface roughness parameters, the average or the mean slope of the profile was found to explain the variations best. Under lubricated conditions, stick-slip phenomena was observed, the amplitude of which depends on the plowing component of friction. The presence of stick-slip motion under lubricated conditions could be attributed to the molecular deformation of the lubricant component confined between asperities. (C) 2009 Elsevier B. V. All rights reserved.

Influence of tilt angle of plate on friction and transfer layer—A study of aluminium pin sliding against steel plate

In the present investigation, unidirectional grinding marks were attained on the steel plates. Then aluminium (Al) pins were slid at 0.2°, 0.6°, 1.0°, 1.4°, 1.8°, 2.2° and 2.6° tilt angles of the plate with the grinding marks perpendicular and parallel to the sliding direction under both dry and lubricated conditions using a pin-on-plate inclined sliding tester to understand the influence of tilt angle and grinding marks direction of the plate on coefficient of friction and transfer layer formation. It was observed that the transfer layer formation and the coefficient of friction depend primarily on the grinding marks direction of the harder mating surface. Stick-slip phenomenon was observed only under lubricated conditions. For the case of pins slid perpendicular to the unidirectional grinding marks stick-slip phenomenon was observed for tilt angles exceeding 0.6°, the amplitude of which increases with increasing tilt angles. However, for the case of the pins slid parallel to the unidirectional grinding marks the stick-slip phenomena was observed for angles exceeding 2.2°, the amplitude of which also increases with increasing tilt angle. The presence of stick-slip phenomena under lubricated conditions could be attributed to the molecular deformation of the lubricant component confined between asperities.