Hydraulic Press Machine Research Articles

Effect of Selective Heating on Formability and Densification of Powder Metallurgy Preforms During Upsetting

In this work, a new method of selective heating is proposed to increase the deformation behaviour of cylindrical sintered aluminium preforms during the process. Initially, cold upsetting is carried out using 0.5 MN hydraulic press machine at 0.1 s−1 strain rate and the failure locations of the preforms are predicted for various initial relative densities with the aspect ratio of 1 during the deformation process. After the prediction of this failure location, various conditions of selective heating are attempted uniformly on the deformed preforms after a certain stage of deformation before the onset of the failure initiation, using portable gas cartridge at a different temperature and time to assess their consequence on formability behaviour. The detailed experimental results are evaluated for the formability of the selectively heated preforms under different variables such as flow stress, relative density, axial strain, formability stress index and stress ratio parameter. As a result, the initiation of failure and its progression can be delayed by selectively heating the samples before the onset of the failure initiation. Selective heating of the failure location may relieve the accumulated stresses and delay the onset of failure to a later strain level thereby increasing the formability of the metal.

Estimation of dynamic behaviors of hydraulic forging press machine in slow-motion manufacturing process

In this paper, stick–slip phenomenon of hydraulic forging press machine (HFPM), a nonlinear manufacturing system subjected to weak rigidity and negative friction velocity gradient, was investigated in slow-motion process. Dynamic characteristics of non-smooth motion were investigated experimentally under various operating conditions in slow-motion process. Taking into account the quadratic and cubic nonlinearities, the governing equation of the HFPM was derived. The method of multiple scales was employed to obtain approximate solution for velocity oscillation during slow motion. The steady-state responses for each case (i.e., non-resonance, primary, super-harmonic and sub-harmonic oscillation) were examined to investigate the correlation between velocity oscillation and nonlinear vibration in slow motion. The effects of viscous damping coefficient, hydraulic stiffness, friction parameters, excitation amplitude and frequency on the amplitude–frequency response characteristics were studied, and the interaction between system dynamics and tribological effects were presented. The stability of operational conditions and the critical velocity of the forging process were analyzed through the bifurcation techniques. Experimental results conducted on the HFPM verify the effectiveness of the proposed method.

Utilization of Plastic Waste Polyethylene Terephthalate (Pet) as a Coarse Aggregate Alternative in Paving Block

PET plastic waste is found everywhere in Banjarbaru City compared to other plastic wastes. It is an excellent prospect to reuse the PET plastic waste. The demand of mountain rock and stone from natural resources increases as happened in Aranio Sub District, Banjar Regency. This research is expected to find one way of suppressing the growth of the number of stone mines or natural stone. Based on SNI 03-0691-1996, the classification of the paving block differentiated according to its usage class, one of which is the C quality used by pedestrians. PET waste used as a coarse aggregate previously processed into aggregate with the ratio of cement material, fine aggregate, a coarse aggregate of 1:6:4. PET waste is processed by melting PET and forming into aggregates. The paving with PET waste process by a hydraulic press machine and tested for strength after 28 days. The result of weight measurement with the specimen increases the amount of PET in the paving block mixture, the paving weight decreases as well as the compressive strength.

The Effect of Microstructures and Hardness Characteristics of Recycling Aluminium Chip AA6061/Al Powder On Various Sintering Temperatures

Aluminium is a metal that has been widely used for commercial applications in the transportation, construction and aerospace industries. Previous studies on recycling aluminium have shown that a lot of energy was used to recycle the aluminium by using conventional method. Therefore, this study was carried out to discover the effect of sintering temperature on physical and mechanical properties of the recycled aluminium chip (AA6061) and aluminium powder with the particle size of 25µm by using a direct conversion method which is the powder metallurgy has been used. The samples were fabricated by using hydraulic press machine at 9 tonnes for 20 minutes. Since this study was focused on the sintering temperature, the samples were sintered at four different temperatures which were 520°C, 552°C, 585°C and 617°C. This study involved two types of tests which were the physical and mechanical test. The physical test involved microstructure observation, density test, porosity test, whereas, the mechanical test involved hardness test. Based on the results obtained, it can be concluded that the sintered temperature at 552°C was the best result of sintered sample to obtained better physical and mechanical for the recycled aluminium chip (AA6061).

Characteristic, Microstructure and Properties of Dense Hydroxyapatite Ceramic from Cockle Shell for Biomaterials

Dense hydroxyapatite ceramic can be fabricated from hydroxyapatite (HA) powder prepared from cockle shells. The shell powder was treated at 900°C and co-precipitated with PO43- in NH4H2PO4 solution at Ca/P ratio of 1.67 in order to synthesize the HA powder. HA discs were formed by a hydraulic press machine and sintered at temperature of 1250°C for 2 h in an electric furnace which helps to dense ceramic. The results from FTIR analysis identified the functional groups of HA powder that has the ion stretching vibration around 3574, 2002 cm-1 for hydroxyl group (OH-), 1451 cm-1 for carbonate (CO32-), and phosphate groups (PO43-) were also observed around 1045 and 560 cm-1 respectively. XRD measurement showed that the ceramic contains hydroxyapatite crystals with β-tricalcium phosphate and calcium oxide as the secondary phase. Morphological evaluations by SEM measurement shows that the HA particles were agglomerated and showed the fractured surface of dense HA when sintered at 1300°C. Grain size ranges from 0.5–1 mm, with an apparent porosity of about 50% of the total area and the pore size ranges from 1–10 mm. Mechanical property measurements show that the dense ceramic contains bending strength of 135 MPa, which is close to the strength of human’s cortical bone (162 MPa).

Numerical and Experimental Investigation on the Effect of Billet Preforming in the Flange Forming

Finite element method and experiments have been used to study a cold forming method for fabrication of a flange using the effect of billet preforming. Three dimensional finite element methods carried out to obtain the forming load, die filling, material flow, effective stress, effective strain with DEFORM-3D software, and a series of experimental works has been performed using lead metal with four types of billet preforming in the first stage. Pressing process has been done using computerized hydraulic press machine with 100 tons. The forming sequence is carried out in two stages. In the first stage, the cylindrical billet is preformed by upsetting and in the second stage forming it in a die. Results indicate that the process of formation is influenced by preforming of billet with fixed volume in the final stage of pressing, improve the mechanical properties of the metal and thus facilitates the final deformation process with less stress and better flow of the metal inside the die. Simulation results show that the effective stress, maximum principal stress, effective strain, velocity and damage are maximum at locations where flange open out and rib growth begins across the geometrical interlocking between the two halves of die-set and the component surface.

Model predictive force control of hardware implementation for electro-hydraulic servo system

This manuscript introduces the application of Model Predictive Control (MPC) for high force control precision in a real industrial electro-hydraulic servo system (EHSS). Moreover, it presents a fractional order control (FOC) and conventional controllers (CC) based on genetic algorithm (GA). The GA technique has been used to tune the parameters of FOC and CC approach. In order to verify the ability of the proposed controller applied to the hydraulic press machines emulator using EHSS, a hardware implementation of a test press system is also suggested and setup to be used in this research. As a result, the study has been investigated using a simulation model then verified via the experimental implementation. In fact, the EHSS plays an important role in many industrial applications, especially in flight simulators, aircraft landing gear system, material testing machine and hydraulic press machines for which the high accuracy and fast response of the force or pressure control are exceedingly necessary. Real-time experiments on the EHSS are carried out to evaluate the proposed control approach in a large system parameters variation of working environments. Considerable improvement in the performance generated by the designed MPC controller is compared with the traditional and fractional order controllers. Moreover, the results show that the performance criteria in terms of settling, rise times, system overshoots, system parameters variation and applying different test signals are good values in case of applying MPC over using FOC and CC in this study. As a general conclusion, one can conclude that the MPC has the priority of applying it in the field of the industrial EHSS. The obtained results are promising in the field of mechatronic.

The Mechanical Response of a Structural Epoxy Adhesive Reinforced with Carbon Black Nanoparticles.

The influence of the concentration of carbon black nanoparticles on the mechanical behavior of a structural adhesive was studied to evaluate and understand the stiffness, strength, and deformation behavior of a reinforced epoxy adhesive. Two carbon black nanoparticles with different dielectric properties and sizes (Monarch® 120 and Vulcan® XC72R) were studied. A bi-component structural epoxy adhesive was selected. Specimens with different concentrations of carbon black were manufactured (0, 5, 10, and 20% on volume of resin) for each type of nanoparticle. The specimens were cured in a hydraulic hot-plates press machine. The mechanical behavior of the adhesives was found not to vary significantly as a function of carbon black nanoparticles amount. A scanning electron microscopy analysis was performed to evaluate the fracture surface. The fracture surfaces of specimens were correlated with the mechanical response obtained through tensile tests.

Physical Properties and Compressive Strength of Zinc Oxide Nanopowder as a Potential Dental Amalgam Material

In this study, the application of nanotechnology was applied in the dentistry field, especially in the innovation of dental amalgam material. To date, mercury (Hg) has been used widely as dental amalgam material with consideration of the cheap price, ease of use, and good mechanical strength. However, last few years, many problems have been faced in the dentistry field due to the use of mercury. Hence, new material is needed as an innovation to eliminate the mercury from dental amalgam composition. This research was conducted to analyze the physical properties and compressive strength of zinc oxide (ZnO) nanopowder as a potential dental amalgam material. The physical properties such as morphology and dimensions were analyzed by SEM and XRD. Further, the compression test was conducted by using hydraulic press machine. The results showed that the ZnO nanopowder analyzed has the particle size of 14.34 nm with the morphology classified as nanorods type. On the compression load of 500 kg, the average of ZnO green density is 3.170 g/cm<sup>3</sup>. This value experienced the increase of 4.763% when the load was set to 1000 kg, and 7.539% at 2000 kg. The dwelling time also took the same effect. At 30 seconds, the average of ZnO green density is 3.260 g/cm<sup>3</sup>. This value experienced the increase of 0.583% at 60 seconds and 3.098% at 90 seconds.

Analisis Sifat Fisik dan Kompresibilitas Nanopowder Zinc Oxide (ZnO) sebagai Alternatif Material Amalgam

Severe effects of the mercury use on health as an amalgam material have required an alternative material in order to eliminate it from amalgam composition. This research was conducted to analyze the physical properties and compressibility of ZnO nanopowder as an alternative amalgam material. The physical properties including morphology, dimensions, and the atomic ratio were analyzed by SEM, XRD-XRF and EDX. Further, the compressibility was conducted by using hydraulic press machine. The results showed that ZnO has particle size of 14.34 nm with morphology classified as nanorods. In the compressibility test, both the variation of compression loadings and holding time have brought an effect on the significant increase of ZnO nanopowder density.

Studies on the synthesis and characterization of polyaniline-zeolite nanostructures and their role in carbon monoxide sensing

Polyaniline was modified with zeolite LTL to increase its response towards carbon monoxide. The synthesis was carried out by chemical oxidative polymerization using ammonium peroxydisulfate (NH4)2S2O8 as oxidizing agent. Zeolite LTL and its ion exchanged forms (Na, Fe, Cu and H-form) were converted into composites. The dry mixed composites were subsequently pressed into pellets with a diameter of 12 mm and a nominal thickness of 2 mm, using hydraulic press machine at a pressure of ∼280 Mpa. The carbon monoxide response measurements were performed for various forms of PANI/LTL at various CO concentrations. The response was found to be maximum for PANI/Na-LTL.

Panel Board From Coconut Fibre And Pet Bottle

The rate of global deforestation and its impact on the environment has led particle board manufacture to search for alternative feedstock, especially in countries where wood is less available compared to other cellulosic natural product. Based on the properties of coconut fibre and PET bottle, these two materials can be recycle as raw material for manufacture of panel board. As for this study, the coconut fibre were used as the filler and PET bottle as outer lining of the panel board. Two types of coconut fibre were used which are grinding and un-grinding coconut fibre. At first, the coconut fibre are undergoes softening, grinding, drying and sieving process, while PET bottle was cleaning, shredding, sieving before compacted using hydraulic hot press machine. There are four types of testing that been carried out which are swelling, water absorption, Modulus of Elasticity (MOE) and Modulus of Rupture (MOR). The result show the conventional board has the highest value for MOE test, so it’s indicate that the conventional board is less strength from the coconut fibre board. As for water absorption test, the average water absorption of coconut fibre based panel board is less than conventional board. Overall, the coconut fibre board is better than conventional panel board because coconut fibre board are less swelling, has low water absorption, high modulus of rupture and low modulus of elasticity. Based on the finding, this coconut fibre panel board has potential as a stronger and long-lasting panel board than the conventional board in the market. Other than that, the panel also have their own aesthetic value since the recycled plastic bottle used as outer lining is colourful and giving aesthetic value.

Phase formation and microstructure of gamma irradiated Bi-2223 Superconductor

The Bi-2223 superconductor has been synthesized using the conventional solid state reaction method. The effect of gamma irradiation on phase formation and microstructure of high-temperature Bi-2223 superconductor ceramic was investigated. The bulk samples sample were palletized with 7 tons pressure of hydraulic press machine and sintered at 840°C for 48 hours. The gamma irradiation was performed at the Nuclear Malaysian Agency with dose of 50 kGray at room temperature. Structure characterization using X-ray diffraction (XRD) showed that the patterns for all the samples demonstrate well-defined peaks all of which could be indexed on the basis of a Bi-2223 phase structure. However, for irradiated sample, it showed reduction in the peak intensity indicating a decrease in the content of the Bi-2223 superconducting phase. The effect of gamma (γ) irradiation on surface morphology and its composites has also been investigated by scanning electron microscope (SEM) and the micrograph shows that the grains are distributed randomly with poorly connected inter and intra-grain microstructure. This shows that the morphology of the Bi-2223 superconductor is very sensitive to gamma irradiation. The effect on the phase formation and microstructure of non-irradiated and gamma irradiated of Bi-2223 superconductor is compared and evaluated.

Comparison of tensile behaviour of polypropylene, aramid and carbon fibre reinforced cementitious composite at high strain rate loading

This paper presents an experimental study on uniaxial mechanical properties of polypropylene, aramid and carbon micro-fibre reinforced high performance cementitious composite subjected to both static and high strain rate tensile loading. This cementitious composite is intended to be used as a matrix for slurry infiltrated fibre concrete, which is being developed to be used for elements and structures for blast, ballistic and other impact protection. Cylindrical specimens of 30 mm diameter and 15 mm thickness were subjected to the indirect tensile (Brazilian) test at loading rate about 5.10-5 GPa.s-1 (quasi-static load regime) and 2.103 GPa.s-1 (high strain rate load regime). Specimens were tested using servo hydraulic press machine and 15 mm diameter Split Hopkinson pressure bar. Dynamic strength increase factor and fibre reinforcement factor have been studied versus both strain-rate and fibre type. Indirect tensile strength and post peak behaviour vary for specimens with different micro-fibre reinforcement, which allows to find the optimal reinforcement for high strain rate impacted concrete structures.

Influence of alumina and silica addition on the physico-mechanical and dielectric behavior of ceramic porcelain insulator at high sintering temperature

The high-strength electrical porcelain insulator plays a vital role in the power industry. The present study investigates the effect of alumina and silica addition on the physico-mechanical and electrical properties of porcelain bodies over high sintering temperatures. The pallets were prepared in different shapes and dimensions with the help of hydraulic press machine by pressing at 160MPa for a period of 10-min. Different characterizations techniques such as; dilatometer, X-ray diffraction (XRD), and scanning electron microscopy (SEM) used to evaluate the thermal, structural, and microstructural changes, respectively by increasing the concentration of silica (0–20wt.%) and decreasing alumina (45–25wt.%) concentration for the base composition of porcelain insulator. The measurement of mechanical strength and physical behavior were analyzed for all the samples prepared with different compositions of alumina and silica with varying sintering temperature (1250 and 1350°C). The sample with a composition having silica 10wt.% of alumina 35wt.% and sintered at 1350°C, shows the maximum density of 2.55g/cc with water absorption of 0.94%. This sample also shows the highest value of bending and compressive strength of 129±5 and 202±5MPa respectively. The highest dielectric value of 5.75 and minimum dielectric loss of 0.05 at a frequency (2–20GHz) is achieved for the same composition with silica 10wt.% of alumina 35wt.% sintered at 1350°C. The composition having silica 10wt.% with alumina 35wt.% sintered at 1350°C, has enormous potential to serve as a high strength refractory and a dielectric ceramic material for microwave applications.

Pemanfaatan Bekas Adukan Mortar pada Pratikum Batu (Masonry) untuk Paving Block

Stone Construction Laboratory is one of the existing courses in the Department of Civil Engineering Polytechnic State of Padang. Students are required to practice firsthand the theories about stone construction that have been studied. Stone work or often called masonry is wall or brick installation work for floor, wall, or fence. In practicum stone, the material used is artificial stone like brick and can also natural stone by using an adhesive substance usually known by the name of spesi or mortar.Mortar or spesi is one of the building materials that serves to glue the pairs of bricks, brick, stucco and so on. Mortars consist of sand, cement and water. In a stone work practicum where the work is not permanent (unloading pairs) then the cement material is replaced by lime which is a temporary binder. So far, the rest of the mortar use for the stone practicum is just thrown away because it cannot be used anymore, therefore it takes alternative utilization of the former mortar, for that the author tries to research by using it to make paving blocks. Paving blocks or concrete bricks for floors are a component of building material made from a mixture of hydraulic cement or the like, aggregates and water with or without other additives which do not reduce the quality of the paving blockThe study used comparison between paving block with mixed composition of mortar, cement and water mixture and paving block with standard mixture composition ie cement, sand and water. Paving is made by pressing using hydraulic press machine with a compressive strength of 25 kg and compressive strength testing with Universal Testing Machine.Based on the results of the research, it was found that the paving block from the utilization of mortar has a compressive strength higher than the standard paving block. At the age of 14 days, the compressive strength of the paving block from the utilization of mortar used has a compressive strength of 76.14 kg

Application of diethanolamide surfactant derived from palm oil to improve the performance of biopesticide from neem oil

The purpose of this research was to improve the performance of organic pesticide derived from neem plant using diethanolamide surfactant (DEA) derived from palm oil in controlling armyworms. The pesticide was made of neem oil. Neem oil is a neem plant product containing several active components, i.e. azadirachtin, salanin, nimbin, and meliantriol which act as a pesticide. DEA surfactant acts as a wetting, dispersing and spreading agent in neem oil pesticide. The neem oil was obtained by pressing neem seeds using a screw press machine and a hydraulic press machine. DEA surfactant was synthesized from methyl esters of palm oil olein. Pesticide formulation was conducted by stirring the ingredients by using a homogenizer at 5,000 rpm for 30 minutes. Surfactant was added to the formulation by up to 5%. Glycerol, as an emulsifier, was added in to pesticide formulations of neem oil. The efficacy of the pesticides in controlling armyworms fed soybean leaves in laboratory was measured at six concentrations, i.e. 10, 13, 16, 19, 22, and 25 ml/L. Results showed that the neem oil used in this study had a density of 0.91 g/cm3, viscosity of 58.94 cPoise, refractive index of 1.4695, surface tension of 40.69 dyne/cm, azadirachtin content of 343.82–1.604 ppm. Meanwhile, the azadirachtin content of neem seed cake was 242.20 ppm. It was also found that palmitic (31.4%) and oleic (22.5%) acids were the main fatty acids contained in neem oil. As the additive material used in neem oil in this study, diethanolamide surfactant had a pH of 10.6, density of 0.9930 g/cm3, viscosity of 708.20 cP, and surface tension of 25.37 dyne/cm. Results of CMC, contact angle, and droplet size analyzes showed that diethanolamide surfactant could be added into insecticide formulation by 5%. Results of LC tests showed that on Spodoptera litura the LC50 and LC95 values were 13 and 22 ml/L, respectively. Neem oil was found to inhibit the development of Spodoptera litura and its larval molting process.

Novel superabsorbent membranes made of PVA and Ziziphus spina-christi cellulose for agricultural and horticultural applications

Novel superabsorbent membranes consisting of polyvinyl alcohol (PVA), cellulose nanocrystals (CNCs) from Ziziphus spina-christi fibers (ZSP-fibers), glutaraldehyde (GLA) and glycerin (G) were prepared using a Hydraulic Lamination Hot Press machine.

A novel topology optimization method of welded box-beam structures motivated by low-carbon manufacturing concerns

This paper proposes a simple and effective topology optimizer to get the best-possible layout scheme of welded box-beam structures that emit less greenhouse gases (GHGs) in manufacturing stage than has been common practice. Firstly, a cradle-to-gate approach is adopted to identify the relationship between the GHGs emission of welded box beams in manufacturing stage and the variables of topology optimization (thickness and coordinates of the stiffener plates). Then, a low-carbon design framework is built to realize the simultaneous handling of GHGs emission reduction and structure layout reconfiguration. Unlike the conventional optimization methods, the proposed method releases more flexibility in representing geometry and topology change during the optimization procedure. As a result, stiffener plates are allowed to move freely within the box beams so as to form a global optimized layout solution. The proposed method is finally applied to the re-design of a welded sliding beam of the hydraulic press machine, on which the numerical analyses conducted exemplify the GHGs emission reduction and structural performance enhancement, and therefore is a good choice for the low-carbon design of large-scale welded engineering structures.

Alternative blade materials for technical and ecological optimization of a hydraulic pressure machine

The Hydraulic Pressure Machine (HPM) is an energy converter to exploit head differences between 0.5 and 2.5 m in small streams and irrigation canals. Previous investigations show that efficiencies above 60% are possible. Several case studies indicate good continuity for aquatic life (e.g. fish) and bed load for the technology. The technology is described as an economically and ecologically viable option for small scale hydropower generation. Primary goal of this research is to improve the HPM blade design regarding its continuity properties by maintaining good efficiency rates. This is done by modifying the blade tip and testing within a large physical model under laboratory condition. Blade tips from steel (conventional - reference case) and a combination of EPDM rubber and steel as sandwich construction (rubber, steel, rubber - adhesive layered) are tested and compared. Both materials reach similar values for hydraulic efficiency (approx. 58%) and mechanical power output (approx. 220 W). The variation of different gap sizes pointed out the importance of small clearance gaps to reach high efficiencies. For assessing the two blade tip materials regarding continuity for aquatic life, fish dummies were led through the wheel. Analysis of slow motion video of dummies hit by the blade show significant advantages for the EPDM blade tip. The EPDM rubber allows to bend and thus reduces the shock and the probability for cuts on the fish dummy. It was shown that blade tips from EPDM have certain advantages regarding continuity compared to standard blade tips from steel. No compromise regarding energy production had to be made. These results from the HPM can be transferred to breast shot water wheel and may be applied for new and retrofitting projects.