Aluminum Profiles Research Articles

Surface defect detection of vehicle light guide plates based on an improved RetinaNet

Aiming at the vehicle navigation light guide plate (LGP) image characteristics, such as complex and gradient textures, uneven brightness, and small defects, this paper proposes a visual inspection method for LGP defects based on an improved RetinaNet. First, we use ResNeXt50 with higher accuracy under the same parameters as the backbone network, and propose the lightweight module Ghost_module to replace the 1 × 1 convolution in the lower half of the ResNeXt_block. This can reduce the resource parameters and consumption, and speed up training and inference. Second, we propose and use an improved feature pyramid network module to improve the feature fusion network in RetinaNet. It can more effectively fuse the shallow semantic information and high-level semantic information in the backbone feature extraction network, and further improve the detection ability of small target defects. Finally, the defect detection dataset constructed based on the vehicle LGP images collected at a industrial site, and experiments are performed on the vehicle LGP dataset and Aluminum Profile Defect Identification dataset (Aluminum Profile DID). The experimental results show that the proposed method is both efficient and effective. It achieves a better average detection rate of 98.6% on the vehicle LGP dataset. The accuracy and real-time performance can meet the requirements of industrial detection.

A virtual testing methodology for the identification of optimal parametric concept models in multi-bolted composite applications.

Virtual Testing (VT) aims to develop finite element (FE) models that represent accurately the structural behaviour of a real product, such that less time is lost in time-consuming and costly physical experiments. However, detailed modelling and advanced simulations for certain applications (e.g. joints or composite materials) involve a number of challenges such as high computational cost and poor convergence due to the large nonlinearities involved in the process. To overcome these issues, we propose a VT methodology with a strong focus on joining technologies, which aims to deliver parametric concept models able to represent faithfully the highly nonlinear behaviour of detailed FE models at different scales. The methodology has been validated in a use case consisting of a composite panel connected to two aluminum profiles through 8 high-strength steel bolts. Applying the VT methodology on the 8 bolts resulted in a reduction of computational time of approximately a factor of 50, while keeping the error consistently below 10%.

Improvement of the mechanical properties in hybrid structures by polyurethane rigid foams reinforcement in aluminium profiles

One of the biggest challenges in transport industry is weight reduction. The objective is both economic and environmental: cost reduction together with a reduction in the use of fuel and CO2 emissions. Multi-material design, with rigid foams as local reinforcements, suppose a great opportunity to success this challenges, being a versatile solution for cost and weight saving. Among them, polyurethane rigid foams (PUR) not only present structural and energy absorption advantages, but also improveme other properties, as corrosion resistance and vibration and noise reduction. In the present work, extruded profiles (series 6xxx-T6) were reinforced with PUR foams manufactured by CETEC. The influence of the next factors on the structural strength has been evaluated: profiles wall thickness (from 1.6 to 4 mm), filling method (manual or injection), PUR density (from 100 to 300 kg/m3), amount of material inside the profiles (from 70 to 90%) and influence of the temperature in the PUR foaming. Improvement in the structural strength (maximum load and energy absorption) was characterised by 3-point bending test. In conclusion, it has been observed an improvement in the load and energy absorption with the inclusion of PUR, with a dependence on the wall tickness and foam density. Furthermore, injected profiles presented improved structural results due to the better control over the manufacturing process.

Fire Resistance of Aluminum-Glass Partitions with a Parallel Structure of Intumescent Layers

Aim: The aim of the article is to verify the fire resistance of aluminum-glass construction partitions with a parallel structure. The paper presents the results of tests in a fire chamber of a selected partition, a leading national manufacturer of aluminum-glass systems. The results of the fire tests were used to validate a simple parallel model of the reliability of non-renewable systems. Introduction: Fire-retardant properties of partitions made of glass and aluminum profiles determine their ability to stop the spread of fire by clos - ing the fire in separate zones. Fire resistance of such partitions is measured according to various criteria, in particular the requirements concern: stability R (glass does not break), tightness E, radiation limitation W and insulation I. The tightness requirement E means that the partition effectively protects the fire compartment against flames, smoke and hot gases. The insulating postulate I means that the average temperature of glass and the profiles on the surface of the partition on the protected side does not exceed the contractual value during the nominal duration of the fire. The measure of fire resistance of a partition is time t, expressed in minutes, in which the structure of an aluminum-glass partition meets one or more of the criteria listed. Methodology: The experimental database consists of the results of routine fire resistance tests of system building partitions obtained in the certification process of selected facade systems. Interpretation of the obtained results of laboratory tests was based on simple models of reliability of non-renewable systems. Conclusions: The graphs of average temperature increase on the outer surface of the tested glass are the same in each case in terms of quality and quantity. Up to about 70% of the nominal fire resistance, the temperature increase is linear, followed by a non-linear phase according to a concave curve. The course of the temperature-rise curves on the outer surface of aluminum profiles is qualitatively different. The graphs are non-linear, convex from the beginning of heating, with the inflection point reached after about 20 minutes of the test. The obtained results may indicate that the multi-chamber structure of aluminum profiles does not ensure a parallel reliability structure, because the object has a quasi-parallel structure. The presented results of the temperature-rise curves and their reliability interpretation require confirmation in further laboratory tests of aluminum-glass partitions with a different structure of panes and profiles. Keywords: glass, partitions, laboratory tests, fire resistance, reliability Type of article: case study

Design and fabrication of 3-axis CNC milling machine using additive manufacturing

High cost of CNC machines is common and huge problem for start-ups, small machinists and also not suitable to be customized. This research mainly focuses on making a cost efficient, affordable, portable and completely customizable CNC milling machine which will be able to work on a wide variety of materials e.g., PVC, Acrylic, Wood & Aluminium. Majority of the components of this machine have manufactured by using 3D printing which will allow the user to customise the machine to suit various needs. To provide structural rigidity aluminium profile extrusions have been used. For the control system an open-source microcontroller-based device (Arduino) has been used. Software used are Arduino IDE & CNCjs, both are among the best open-source software available and have the ability to control a wide variety of CNC controlled systems. For precise motion stepper motors and lead screw setups are used, which is pretty common to all CNC based systems. As far as the customization is concerned, this machine can be customised mainly in two ways. First is dimensionally, to suit a specific sized workpiece and second is functionally, to be used as a milling machine, laser cutter and engraver.

AI-enhanced vision system for dispensing process monitoring and quality control in manufacturing of large parts

Assembly is one of the cornerstones of today’s manufacturing; thus, efficient automated assembly systems have become a necessity in the recent past. Challenges that have traditionally been present in such systems involve positioning accuracy, stable gripping, accommodation of several variants by the same resources and prevention of error aggregation. In robot-based applications the detection of parts and their components is a common task, but when it comes to large objects which cannot be portrayed in single camera frames, the complexity becomes significantly larger. This paper presents an AI based perception system which employs a 3D vision sensor to implement a smart dispensing application and perform online process quality control of large parts assembly. The aim of the system is to provide execution autonomy for a robotic manipulator that is responsible for glue dispensing on different types of aluminium profiles of varying cross-sections, length, and associated glue patterns. By using an eye-in-hand RGB-D camera and employing deep learning methods (Yolov3 algorithm), the framework recognizes the type of profile that is going to be processed, and depth information is used to extract the profile’s points (starting-ending points) on which glue must be dispensed. Point Cloud manipulation (DBSCAN clustering, plane segmentation) and 2D image-based processing were tested during the quality inspection, in order to validate the success and accuracy of the process (detection of glue discontinuities, calculation of the glue volume level). The system has been deployed on a case study involving the assembly of components on buses and the results indicate that a robust recognition and adhesive application can be obtained throughout each operation cycle.

Image Deep Learning Assisted Prediction of Mechanical and Corrosion Behavior for Al-Zn-Mg Alloys

The use of metallographic images to predict the mechanical properties of materials and their corrosion behavior is helpful in achieving nondestructive detection and quality control. However, after a long-term attempt, the traditional methods cannot accurately correlate the mechanical properties and corrosion behavior of materials with the corresponding microstructure images. In this study, we propose a deep learning strategy to predict the mechanical property and corrosion behavior of large-scale extruded aluminum profiles using surface optical microstructure images. The proposed models with remarkable properties were established through experimental dataset collection, dataset preprocessing, deep learning network modification, and key parameter screening. Taking extruded Al-Zn-Mg alloys with different surface microstructures as example materials, 4,800 sets of “metallographic image – hardness (HV) – corrosion potential (E <sub xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">corr</sub> )” data were experimentally collected to establish the HV and E <sub xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">corr</sub> models with prediction accuracies of 90% and 82%, respectively. The proposed HV and E <sub xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">corr</sub> models exhibit great generalization ability with mean average errors of 1.8 HV and 7.0 mV on experimental validation sets, respectively. The proposed model can accurately correlate the metallographic images, mechanical property, and corrosion behavior, which can provide theoretical support for intelligent and nondestructive testing methods to further prevent unexpected material failure.

Target Detection Algorithm for Surface Defects of Complex Aluminum Profiles

Target Detection Algorithm for Surface Defects of Complex Aluminum Profiles

The Modern Conveyor System and its Construction

Rexroth systems are the right solution to move materials and it ensures a smooth transfer of material along the tracks Modern conveyor system is often used in industrial automatization. Presented system offers a full and diverse range of custom conveyor types and solutions. Designed conveyor system is an example of the use of aluminum profiles for students of secondary industrial school as a teaching tool.

Bending degradation of thin-walled box beams made of aluminum omega profile and GFRP panel connected by mechanical fasteners

The paper presents the results of laboratory tests and numerical simulations for thin-walled beams subjected to 3-point bending (3-PB). The beams were made of two parts: an aluminum (7075) omega profile and a GFRP (glass fiber reinforced plastic) panel, which were connected by rivets. The paper focuses on the analysis of deformation states and gradual degradation in these elements. The modeling is described by parameters as the number of rivets, the height of the aluminum profile, and the stiffness of the composite which strongly influence the failure force. The experiments were carried out for two settings of beams on supports, in which the composite panel was located on the side of the supports or on the side of the load acting on the beam axis. The laboratory tests allowed to confirm the correctness of the numerical model. As a result of numerical simulations, the most optimal material and geometric configuration were determined, taking into account the maximum carrying criterion force at 3-PB. The effort of the composite material was also analyzed based on the Tsai-Hill hypothesis.

The Effect of Different Pre-Surface Finishing Method on the Aluminium Anodization of the 6XXX Series Alloy

In this study, the effect of different pre-surface finishing method on the aluminium anodization was investigated for AA 6063 alloy. Within the scope of pre-surface finishing method which is acidic solution concentrations and process time were determined. Acidic solution was determined by using hydrofluoric acid (HF) and nitric acid (HNO3). Also Gresoff LIM-5 LV chemical was used with different concentrations and process time for degreasing process. The etching effect of acidic solution on aluminium samples was investigated. The optimal etching behaviour was obtained with 1.0% concentration of HF and 3.2% concentration of HNO3 at 10 minutes process time. Also optimal surface properties were observed with 1.0% concentration of Gresoff LIM-5 LV at 12 minutes process time. Then anodic oxidation was performed by using 180 g / L sulfuric acid (H2SO4) and 18 volt (V). Surface morphology of the final aluminium profiles were examined with SEM analysis, Roughness, Gloss and Thickness tests.

Research on ultrasonic-assisted multi-point stretch bending process of aluminum profile

The tensile and bending process of asymmetric L-shaped aluminum alloy profile is studied by the Abaqus software using the finite element numerical simulation method. The geometric parameters of the ultrasonic-assisted vibration multi-point die (UMPD) and the law of influence on the stress-strain and spring-back of the L-section profile after bending are studied. The results show that the UMPD can reduce the forming stress of the profile during plastic deformation, and the stress-strain distribution of the aluminum profile is more uniform. The changes in the ultrasonic vibration frequency and amplitude of the mold are beneficial to reduce the spring-back of aluminum profiles. The ultrasonic process parameters with a vibration frequency of 20 kHz and an amplitude of 0.02 mm have the best effect on suppressing spring-back, which is reduced by 20.6% compared to the case of no ultrasonic application. Finally, it is verified by experiments that the experimental results are basically consistent with the simulation results, and the changing trend of spring-back deformation is consistent.

Acoustic emission as a valuable technique used for monitoring polymer failures

In the paper, acoustic emission (AE) system was presented as a method that can be used to monitor polymer material failures. Samples fabricated of two aluminum profiles bonded together with a thick layer of cured epoxy resin were subjected to fracture tests. Epidian 53 epoxy resin cured with Z1 curing agent as well as Epidian 5 epoxy resin cured with PAC curing agent were selected as adhesives. Acoustic emission parameters were acquired during Double Cantilever Beam (DCB) tests. The frequencies of elastic waves released during failure were then analyzed using both Fast Fourier Transformation (FFT) and Wavelet Transformation (WT) for the two materials.

Technical solution of the modern conveyor system

The modern conveyor system finds its place in industrial automation. It offers a full and diverse range of custom conveyor solutions and types. Aluminium profiles offer huge range of different sizes. Conveyors are useful to move materials and smooth transfer along the tracks. Therefore, this paper aimed to designed conveyor system using by aluminium profiles. The aim of the paper is to point out the issue of modularity of our designed conveyor system through design and technological parameters that directly affect its use for the needs of practice. They can be installed almost anywhere, and they transport loads of all shapes, sizes and weights.

A new extrusion die for aluminum profiles

A new type of extrusion die is put forward, in which cemented carbide material is used to inlay the working part of the die, so as to improve the wear resistance of the die. The necessity of using cemented carbide in extrusion die is introduced. The selection of cemented carbide was introduced by taking the actual round tube aluminum profile as an example. The method for determining the size of cemented carbide and the mosaic method of cemented carbide were described. Based on the results of extrusion, the common extrusion die and cemented carbide extrusion die were compared. The results show that the wear resistance of the die can be greatly improved by the use of cemented carbide. Thus the life of the die is greatly improved.

Proposed Productivity Improvement of 1800 Press Machine Using Overall Equipments Effectiveness

Increased productivity is an effort to increase production capacity by increasing the productivity of each factor of production. PT XYZ is a company that uses sophisticated machines and facilities to produce aluminium profiles that create various needs in the form of building goods or furniture products in the form of doors, windows, partitions, frames, rolling doors, etc. One of the machines used is the 1800 press machine. This study aims to increase productivity with Overall Equipment Effectiveness (OEE) to make improvements. Based on the calculation of the Overall Equipment Effectiveness (OEE) of the 1800 press machine during January - December, the final value was 52%, this value indicates that the effectiveness of the 1800 press machine has not reached the ideal deal of 85% so that some improvements are needed. The company experiences the three most considerable losses: Breakdown Losses, Setup and Adjustment Losses, and Reduce Speed Losses, so repairs must be made to these three losses so that the 1800 press machine can achieve its best performance. Keywords— Overall Equipments Effectiveness (OEE), Six Big Losses, 1800 press machine

Effect of Forming Parameters on Profile Thinning of Flexible 3D Multi-Point Stretch Bending

The ABAQUS finite element simulation software is used to simulate the flexible multi-point three-dimensional stretch bending process of aluminum profiles. The effect of process parameters on the web thickness of rectangular profile in flexible multi-point three-dimensional stretch bending is studied by orthogonal experiment and range analysis. The process parameters used in the experiments include pre-stretching value, post-stretching value, the number of multi-point dies and friction coefficient. The optimal combination of process parameters is obtained by numerical simulation and experimental verification. When the aluminum profile is completed flexible multi-point stretch bending according to the best parameters, the thickness thinning of outer web and inner web is the smallest. The experimental result is closed to the numerical simulated results. The effectiveness of the numerical simulation is verified by the corresponding experimental methods.

On Using Si to Unravel Potential Sources of Dissolved Al to the Deep Arctic

AbstractAn examination of the vertical profiles of aluminum, silicic acid, and the Si:Al ratio indicates that the enrichment of dissolved Al in the bottom waters of the Arctic basins cannot be explained by the water column remineralization of vertically transported biological material. Instead, it is suggested that the bottom water enrichments are a result of the dissolution of amorphous aluminosilicates that are produced within the sedimentary pore waters by a reverse weathering process. We suggest that these materials are released into the low Si, low Al overlying water column by turbidity currents descending from the broad Arctic shelves which deliver sediments, water, and the products of reverse weathering into the bottom waters of the Arctic basins. It is suggested that from its delivery point at the basin edges, this dissolved Al signal then spreads out, enriching the signals in the bottom of the basins and mixes upward into the overlying water column to produce the observed vertical gradients. Thus, the deepwater Al enrichment is driven by a concentration gradient from below, that is, it is a bottom up (sedimentary driven), rather than the top down (particle export) process that has been previously suggested. It is also suggested that this dissolved Al signal might potentially be used as a tracer of these sporadic turbidity events, which in addition to transporting sediments, also are a mechanism for subducting water into abyssal regions. The observation of elevated dissolved Al signals at other ocean boundaries adjacent to Al‐rich lithogenic materials further suggests that the formation of the products of reverse weathering within sediments is probably widespread along continental margins.

Financing strategy to support a product development of aluminium finished goods (case study: PT. XYZ)

Nowadays, the use of wood materials for construction is starting to be reduced because it can cause global warming due to cutting down forests. There are changes in the construction used aluminium materials such as frames and doors. There is an increasing demand for aluminium products which is an opportunity for companies to develop products. Currently the company manufactures aluminium profile products (semi-finished goods), so the company needs to develop aluminium finished goods products to increase profits and brand image. The investment required by the company is 11,232,000,000 rupiah to develop aluminium finished goods products. This research uses financial feasibility study, then selects the best investment financing. Net Present Value (NPV), Profitability Index (PI), Internal Rate of Return (IRR), Payback Period (PP), and Return on Investment (ROI) are used as variables for determining investment. There are four financing alternatives, including internal financing, bank, leasing and IPO. The results showed that bank financing provided the highest NPV and ROI with an NPV value of 1,546,356,903, Profitability Index (PI) of 1.14, Internal Rate of Return (IRR) of 10.09%, Payback Period of 4 years 1 month, Return on Investment (ROI) of 28.24% and US Index of 4.71. Thus, the results of this research recommend using bank financing for investment in product development.

Improving Production Efficiency with a Digital Twin Based on Anomaly Detection

Industry 4.0, cyber-physical systems, and digital twins are generating ever more data. This opens new opportunities for companies, as they can monitor development and production processes, improve their products, and offer additional services. However, companies are often overwhelmed by Big Data, as they cannot handle its volume, velocity, and variety. Additionally, they mostly do not follow a strategy in the collection and usage of data, which leads to unexploited business potentials. This paper presents the implementation of a Digital Twin module in an industrial case study, applying a concept for guiding companies on their way from data to value. A standardized use case template and a procedure model support the companies in (1) formulating a value proposition, (2) analyzing the current process, and (3) conceptualizing a target process. The presented use case entails an anomaly detection algorithm based on Gaussian processes to detect defective products in real-time for the extrusion process of aluminum profiles. The module was initially tested in a relevant environment; however, full implementation is still missing. Therefore, technology readiness level 6 (TRL6) was reached. Furthermore, the effect of the target process on production efficiency is evaluated, leading to significant cost reduction, energy savings, and quality improvements.