Manufacture Of Plates Research Articles

ОСОБЕННОСТИ СТРУКТУРЫ СОЕДИНЕНИЯ В ЗОНЕ РЕМОНТА СВАРКОЙ ВЗРЫВОМ ДЕФЕКТОВ СПЛОШНОСТИ БИМЕТАЛЛИЧЕСКИХ ПЛИТ СТАЛЬ-ТИТАН

The paper studies microstructures in a welded joint of a titanium cladding layer. This joint was obtained by repeated cladding by explosion welding of defects that arose during the manufacturing of bimetallic plates "steel + titanium" by explosion welding. When removing titanium from the defect zone in the cladding layer, the transition zone was ground at an angle to the steel surface. It is shown that the structure of the welded joint is determined by the impact angle at the bevel section and the direction of the outflow of shock-compressed gas from the welding gap. The revealed structural features help to select the bevel angle to obtain a high-quality connection when repairing defects by explosion welding. The bevel angle on the edges should be ground so as to obtain a theoretical impact angle greater than the minimum and less than the maximum welding angle (however, the minimum possible welding angle at the beginning of the explosion welding process).

Experimental investigation of an additively manufactured cold plate for multi-chip module cooling generated using the homogenization approach to topology optimization

The homogenization approach to topology optimization is promising for generating high-performance, liquid-cooled cold plates due to its ability to create sub-resolution features by optimizing the spatial distribution and porosities of physical microstructures. This optimization capability has been demonstrated for the design of compact microchannel heat sinks under uniform heating conditions. However, there is a need to understand its applicability for practical applications involving complex boundary conditions posed by modern electronics packaging requirements. This work performs the topology optimization, design for manufacturing, fabrication, and experimental testing of a liquid-cooled cold plate for an application-representative multi-chip module with eight devices. The cold plate design requirements and boundary conditions involve eight equally spaced heat generating sources and liquid inlet/outlet ports that are off-center, introducing flow distribution challenges to the thermal design. A topology optimization algorithm is developed using the homogenization approach with circular pin fins chosen as the microstructure. An empirical permeability correlation for pin fins is developed which is implemented in the porous media flow model of the topology optimization algorithm to simulate pressure drop across additively manufactured pin fins. In addition to the topology optimized designs, a benchmark cold plate design with uniformly distributed 1.2 mm diameter pin fins, representative of the feature dimensions currently adopted in applications for the investigated boundary conditions, is also evaluated. Comparison of the topology optimized cold plate generated using the design freedom brought by additive manufacturing to the benchmark design highlights the optimizer’s ability to uniformly distribute the coolant amongst the heated regions. The maximum base temperature rise is 35.5 °C for the benchmark design versus 6.6 °C for the topology optimized design. Flow uniformity combined with the high convective heat transfer of the sub-resolution fins and channels in the vicinity of the heated regions keep the device temperatures low. The topology optimized cold plate is additively manufactured and experimentally tested at various flow rates. The experimental results match well with the model predictions, with a mean absolute percentage error of 5.5 % and 9.7 % for pressure drop and thermal resistance respectively, indicating that the optimal performance promised by the algorithm can be realized using additively manufactured parts. The work presented here demonstrates the overall process flow for the homogenization approach in leveraging the capabilities of additive manufacturing to generate high-performance liquid cold plates for practical applications.

Optimizing System Efficiency and Reliability: Integrating Semi-Markov Processes and Regenerative Point Techniques for Maintenance Strategies in Plate Manufacturing

This paper offers a modeling methodology to evaluate similar systems’ performance and optimize system effectiveness with customized maintenance plans. This strategy, which combines regeneration point techniques with semi-Markov processes, is used to assess a plate manufacturing company’s system. Key insights are obtained using a thorough cost-benefit analysis that includes numerical analysis, graphical interpretations, and system efficacy indicators. The study clarifies the dynamics of the system’s reliability under different repair rates by showing an inverse relationship between Mean Time to System Failures (MTSF) and failure rate. Additionally, the analysis clarifies how profit is affected by failure rate, highlighting the necessity of efficient maintenance plans from an economic standpoint. This research highlights the growing significance of availability and dependability in technology-driven sectors and emphasizes the need for dependable systems. This paper makes a substantial contribution to the knowledge already available in the field of reliability engineering by providing a thorough framework that combines regeneration point approaches and semi-Markov processes. The metrics that are obtained offer a comprehensive understanding of the behavior of the system, which in turn helps industry practitioners make well-informed decisions.

Study on the forging process of artificial bone plates of SUS 316L

Abstract SUS 316L stainless steel, valued for its strength and biocompatibility, is a popular choice for artificial bone plates. Forged SUS 316L plates offer advantages like enhanced strength, improved fatigue resistance, reduced material waste, and increased production efficiency. Consequently, the forging technology and die design for SUS 316L is crucial in the manufacturing of high quality artificial bone plates. Finite element analysis simulates the forging process of SUS 316L bone plates, guiding the selection of the appropriate forging machine, die design, and process parameters based on the resulting forging load, stress distribution, and filling condition. Ultimately, this approach facilitates the creation of high-quality SUS 316L bone plates with precise dimensional accuracy.

Investigation of Kevlar and Basalt fiber hybridization on vibrational characteristics of composite plates

The study of vibrational characteristics of plates, specifically composite plates, has gained significant importance in contemporary and cutting-edge industries involved in industrial plate manufacturing. This paper investigates the vibrational behavior of composite plates made of Kevlar, basalt, and a hybrid combination of Kevlar and basalt fibers embedded in an epoxy matrix. The investigation was carried out through experimental methods utilizing the D3560 analyzer device. Furthermore, in order to ensure the reliability of the findings, the experimental data were simulated and compared with finite element modeling using the ABAQUS software. The results demonstrate that hybridizing the fibers in the first and second modes leads to an increase in the natural frequency compared to pure Kevlar, while the hybridization effect compared to pure basalt has a negative impact. However, in the third to fifth modes, the layered arrangement shows an increase in the natural frequency compared to pure Kevlar and pure basalt. The experimental results obtained and the simulated ones in the finite element software exhibit a consistent trend.

Implications of changing the base raw material – the case of license plate manufacturing

ABSTRACT License plates to uniquely identify vehicles mainly use aluminum as the base material. Currently, there is no distinction of different use cases of license plates, such as short-time usage for test drive and transportation purposes that do not need such long-lasting materials not only from cost but also from sustainability perspectives. This paper presents a methodology to select the best material for different use cases under the holistic consideration of specifically defined criteria as to material properties, sustainability aspects, and supply chain implications. We show that there are several candidate materials for different use cases that stick out by changing the importance of these numerous criteria. In addition, the paper delves deeper into the sustainability aspect by means of a comprehensive System Dynamics model. We show that a scenario in which the company picks up used license plates by relying on a logistics service provider to get them delivered to an external recycling service provider yields the best results.

Development and Manufacturing of a Fibre Reinforced Thermoplastic Composite Spar Produced by Oven Vacuum Bagging.

The limited recyclability of fibre-reinforced thermoset composites has fostered the development of alternative thermoplastic-based composites and their manufacturing processes. The most common thermoplastic-based composites are often costly due to their availability in the form of prepreg materials and to the high pressure and temperatures required for their manufacturing. Yet, the manufacturing of economic and recyclable composites, made of semi-preg composite materials using traditional composite manufacturing technologies, has only been proved at a laboratory scale through the manufacturing of flat plates. This work reports the manufacturing of a real structural part, a wing spar section with complex geometry, made of commingled polyamide 12 (PA12) fibres and carbon fibres (CFs) semi-preg and by oven vacuum bagging (OVB). The composite layup was studied using finite element analysis, and processing simulation assisted in the determination of the PA12/CF preform for OVB. Processing of two forms of semi-preg materials was first evaluated and optimised. The material selection for part manufacturing was mainly defined by the materials' processability. The spar section was manufactured in two OVB stages and was then mechanically tested. The mechanical test showed a linear strain response of the prototype up to the maximum load and validated the optimised layup configuration of the composite structure.

Evaluation decision on green degree combination of typical welding processes for large-diameter thick plates

Abstract Aiming at the environmental impact of large-diameter thick plate manufacturing scenarios in the welding process, a comprehensive evaluation method combining AHP and TOPSIS is proposed to analyze and make decisions on the green welding process suitable for large-diameter thick plates. The optimal green welding process evaluation and decision-making index system for large-diameter thick plates is constructed. The system can be flexibly applied to different large-diameter plate welding scenarios by focusing on different optimization objectives, providing welders with a more suitable green welding process. The constructed model is applied to the seashore factory welding scenarios and general welding scenarios for comparative decision-making, and the effectiveness and feasibility of the proposed comprehensive decision-making evaluation method are verified by the actual data calculation results.

Partition five-axis surface machining of CFRP laminate structures considering fiber orientation

ABSTRACT Carbon Fiber Reinforced Polymer (CFRP) is commonly employed in advanced industries, acclaimed for their outstanding mechanical properties. The inherent anisotropy of CFRP necessitates careful consideration of the Fiber Cutting Angle (FCA) to achieve optimal surface quality during machining, a challenge that intensifies with curved surface components due to the continuous variability of FCA. In the machining of CFRP curved surfaces, the presence of local singularity precipitates abrupt changes in tool orientation, adversely affecting surface integrity and machining efficiency. To solve this problem, this study proposed a toolpath partitioning method specifically designed for the machining of CFRP curved surfaces, aiming to mitigate the effects of local singularity. Additionally, a novel tool positioning strategy accounting for dual fiber orientations in the machining of bidirectional CFRP curved surfaces was developed. The practical applicability of these methodologies was assessed through the manufacturing of an internal fixation plate via 5-axis machining of bidirectional CFRP laminates. Comparative microscopic observations and surface profile assessments demonstrate a marked improvement in surface quality relative to traditional 3-axis machining, alongside a 25% reduction in machining time compared to 5-axis machining processes absent the partitioning method.

Simplifying tailored generation of complex structured femtosecond pulses with easily fabricated phase plates.

This article presents a novel approach to targeted 4f pulse shaping using phase plates fabricated by single-point diamond turning (SPDT) machining. The manufacturing of the phase plates using SPDT is versatile, cost-effective, fast, robust, and applicable across a wide range of optical materials, spanning from visible to far-infrared spectra (e.g., PMMA, ZnSe). Manufactured profiles can be used for phase manipulation and pulse structuring, analogously to programable spatial light modulators (SLM). We demonstrate that the pulse waveforms can be reproduced with high fidelity by simple simulations based on calculating optical path differences induced by the phase plate for each wavelength and taking into account the finite focal spot. The simulated and reconstructed frequency-resolved optical gating spectrograms featured G errors between 1-2% and intensity errors between 0.02-0.06. Even for complex structured pulses with the rms value of the time-bandwidth product reaching 12, our method maintains high precision, in some cases even reaching lower G error compared to simpler waveforms. Finally, we also show that the phase plate can be used to attain a set of uncorrelated pulse waveforms by moving the plate relatively to the dispersed laser spectrum. Overall, this approach bypasses common limitations associated with pulse shaping using SLMs, such as pixelation, pixel cross-talk, and spectral or laser fluences constraints.

Mechanical and Fatigue behavior of G22NiMoCr5-6 and G18NiMoCr3-6 used in heavy-duty crawler track plates

G22NiMoCr5-6 and G18NiMoCr3-6 steels are commonly used in the manufacturing of crawler track plates of heavy-duty equipment due to their enhanced mechanical properties which allow them to be suitable for this particular application. This research aims to investigate the mechanical and fatigue behavior of both material grades to evaluate their performance in the manufacturing of heavy-duty crawler track plates. In the present work, experimental investigations were carried out including chemical composition, tensile, hardness, Charpy impact, and low-cycle fatigue tests. Also, metallographic examination was conducted to show the microstructure of both materials. Based on the experimental analysis results, the bainitic structure of G18NiMoCr3-6 was found to have longer fatigue life and higher toughness than the tempered-martensitic structure of G22NiMoCr5-6 which qualifies G18NiMoCr3-6 to be more suitable for manufacturing of heavy-duty crawler track plates than G22NiMoCr5-6 steel.

Optimization, Design, and Manufacturing of New Steel-FRP Automotive Fuel Cell Medium Pressure Plate Using Compression Molding

In this work, a new plastic-intensive medium-pressure plate (MPP), which is part of a fuel-cell system, has been developed together with a steel plate meeting all mechanical and chemical requirements. This newly developed MPP had to achieve the objective of saving weight and package space. The use of compression molding as a manufacturing technique facilitated the use of glass mat thermoplastics (GMT) which has higher E-modules and strength compared to most of the injection molded materials. A steel plate was placed as an insert to help achieve the stiffness requirements. For the development, the existing MPP was benchmarked for its structural capabilities and its underlying functional features. Four different FRP materials were investigated in terms of their chemical and mechanical properties. PP-GMT material, which has both high mechanical performance and resistance against chemicals in the fuel cell fluid, had been chosen. Using the properties of the chosen PP-GMT material, topology optimization was carried out based on the quasi-static load case and manufacturing constraints, which gave a load-conforming rib structure. The obtained rib structure was utilized to develop the final MPP with adherence to the functional requirements of MPP. The developed plastic-intensive MPP exhibits a 3-in-1 component feature with a 55% reduction in package space and an 8% weight reduction. The MPP was virtually analyzed for its mechanical strength and compared with the existing benchmark values. Finally, a press tool was conceptualized and manufactured to fabricate the new plastic-intensive MPP, which was tested in a rig and validated in the FE model.

Analysis of failure characteristics of screen plates of ring hammer crusher used in coal handling applications

The screen plate, a critical component within a ring hammer crusher (also known as a ring granulator or rolling ring crusher), plays a vital role in the secondary crushing of coal. Functioning both as a platform for coal crushing and as a sieve to achieve the desired coal size, it is essential to understand and examine its failure characteristics to enhance its mechanical and wear resistance properties in coal handling applications. This study thoroughly explored the failure modes, mechanisms, and underlying causes of screen plate failures. Microscopic techniques such as optical microscopy (OM), scanning electron microscopy (SEM), Vickers microhardness test and spectrochemical analysis were utilised to identify the failure mechanism. Failure modes identified from the macroscopic analysis were discharged hole widening, hole wall break-off, plate edge crack, plate fracture, one-sided edge slimming, and general surface wear of the screen plate. The fractographic and wear track analysis identified the principal failure mechanisms of three-body abrasive wear, two-body sliding abrasion wear, shear-induced fatigue fracture and brittle shear fracture. The root causes of the failures are the rotor’s direct impact, defects in the parent material, the presence of hard materials in the coal and the use of unsuitable steel grade in the screen plate manufacturing. The service life of the screen plate can be improved through proper material selection, uniform crusher feeding, surface modification of the surface of the “as purchase” screen plate with appropriate wear-resistant materials, and adherence to good maintenance practices.

Safety measures in the workplace: a case study of Federal Road Safety Corps (FRSC) vehicle plate manufacturing plant, Ojodu – Lagos, Nigeria

Introduction: Hazards associated with vehicle number plate manufacturing processes in developing countries have not been well elucidated. There is a need to investigate hazards in the vehicle number plate manufacturing plant. The study aimed to identify self-reported hazards in the vehicle plate manufacturing factory, explore their effect on workers’ health and recommend mitigation strategies. Methods: A descriptive cross-sectional study of workers in the vehicle plate manufacturing plant was done to identify hazards, protective measures and self-reported effects on workers’ health. Biochemical analysis of blood samples was also done and outliers were noted. ANOVA test was performed to determine differences in mean values of selected biochemical parameters. A p-value of less than 0.05 was considered statistically significant. Results: Exposure to toxic chemicals 38(69%), excessive noise 36 (65%) and heat 28 (51%) were the major hazards in the factory. Major health problems were stress and fatigue 41 (71%), skin disorders 28 (51%), respiratory problems 18 (33%) and hearing loss 16 (29%). More than one quarter, 17 (30 %) of the workers admitted not using personal protective equipment (PPE) regularly. Periodic medical tests were not done for 13 (24%) of the workers. Potassium (3%), Urea (10%), Creatinine (7%), Aspartate transaminase (18%) and Alanine transaminase (8%) were elevated among the workers but no significant association could be established between elevated levels and work post. Conclusion: Workers in the plate number manufacturing plant were mostly exposed to toxic chemicals and noise. Elevated electrolyte levels cut across departments. There is a need for better enforcement of safety rules, and periodic medical examinations should be conducted more consistently.

Depth feature fusion based surface defect region identification method for steel plate manufacturing

Computers and electrical engineering have made great strides in steel plate manufacturing. Defect recognition techniques have also evolved. However, due to the large scale of defects, diverse features and sample imbalance problems of steel plates, the general algorithms often suffer from low recognition accuracy and weak robustness in practical detection. Aiming at the problems in recognition, this study proposes an improved defect segmentation network with coder-decoder structure to realize multi-scale interaction of features. Using the split-attention feature extraction module, defect features are learned adaptively. Meanwhile, combined with the group normalization module, a surface defect region recognition model based on depth feature fusion is established. The model was trained for comparative ablation using a migration learning approach. The experimental results confirm the efficiency of the technique. 89.11 % IoU and 94.24 % Dice can be achieved on the Severstal dataset using this method. The research can be applied as an intelligent system for quality monitoring throughout the production process, guiding its rational decision-making and control to realize the improvement of strip steel product quality.

Thermal buckling in multi-directional porous plates: The effects of material grading and aspect ratio

In the present study, a trigonometric shear deformation plate theory was employed to perform a thermal buckling analysis of multi-directional functionally graded (FG) plates. During the manufacturing of the multi-directional graded plate, the formation of pores is abounded. Hence, the effect of porosity on the buckling performance was investigated by considering the variation of porosity in the plate for power law gradation variation of material properties. The adverse effect of porosity on the material properties was taken into account by employing the rule of mixture relation. Finite element results show that the thermal expansion coefficient is unaffected by the presence of porosity. For simply supported boundary conditions, the non-linear governing equations are solved for different thermal loads such as uniform, linear, and non-linear. A parametric study was performed in which the effect of grading parameters, aspect ratio, and side-to-thickness ratio under variable temperature change was studies. Critical material grading indices for multi-directional plates have been identified that help researchers and industry personnel in fabrication planning.

Characterization and prediction of micro channel depth of ultra-thin bipolar plates for PEMFCs

In this study, a combination of experimental and statistical methods were employed to precisely determine the micro channel depth in ultra-thin metallic bipolar plates fabricated from 316 stainless steel with a thickness of 0.1 mm. The investigation centers on the rubber pad forming process and its role in the production of these critical components for Proton Exchange Membrane Fuel Cells (PEMFCs). To advance the understanding of this manufacturing process, experimental tests were designed using a Design of Experiment (DOE) technique and subsequently developed a predictive model using Response Surface Methodology (RSM). The research reveals a direct, quantifiable relationship between the channel depth in metallic bipolar plates and the magnitude of the applied force. Also, the pivotal role of rubber thickness as a dominant factor influencing channel depth was explored. Furthermore, it is revealed that augmenting the channel depth in these plates is attainable through a reduction in rubber hardness and an increase in rubber thickness. However, the benefits diminish once the rubber layer thickness exceeds a specific threshold. Moreover, the results underscore that the primary influential factors in this process include force, hardness, thickness, as well as the interplay between force and rubber thickness. The proposed model's accuracy is reaffirmed through an average error rate of approximately 5.39%, signifying its reliability in predicting microchannel depth. This research contributes novel insights into the manufacturing of ultra-thin metallic bipolar plates for PEMFCs, shedding light on the critical parameters influencing channel depth and their interrelationships. The significance and engineering value of this work lies in its potential for enhancing the design and manufacturing of metallic bipolar plates for PEMFCs. Precise control of microchannel dimensions is crucial for enhancing PEMFC performance and efficiency. This research not only advances clean energy technology but also contributes to the broader goal of achieving sustainable energy solutions, making it a noteworthy and timely contribution to the field.

Restoration of continuous casting machine mold copper plates made of Cr–Zr bronze using multi-pass friction stir lap welding

An innovative technology has been developed and implemented for the restoration and manufacturing of new mold copper plates for continuous casting machines (CCMs) using wear-resistant composite coatings. These copper plates significantly surpass the service life of imported copper plates featuring galvanic coatings, sometimes by up to 20 times. However, the pressing challenge of restoring the copper plates of molds once they have reached the minimum permissible thickness remains unresolved. This study aimed to explore the feasibility of restoring a plate composed of precipitation-hardening Cr–Zr bronze with the same material by employing friction stir lap welding (FSLW). The objectives were to examine the structure, quality, and hardness of the welded joint, alongside investigating the impact of heat treatment (quenching and aging). By utilizing multi-pass FSLW method with a rotating tool crafted from a heat-resistant alloy and overlapping (partially overlapping) successive passes, a welded joint with a thickness of ~5 mm was achieved, devoid of critical continuity flaws (cracks or voids). Within the bronze layer restored through FSW, a softening effect ranging from 85–105 HV1 was observed compared to the initial hardness of the bronze in its hardened and aged state while in service (116–126 HV1). This is attributed to recrystallization and overaging, specifically the coarsening of chromium particles within the Cr–Zr bronze due to the heating of the weld nugget (stir zone) to 600–700 °C. The observed softening effect during FSW can be effectively rectified through heat treatment involving dissolution of the hardening phases followed by aging, resulting in a hardness increase to approximately 120–150 HV1. The process of restoring copper plates to their original thickness via the progressive and environmentally friendly FSW method, followed be the subsequent application of wear-resistant composite coatings, presents the opportunity for an almost infinite operational cycle of molds. This advancement could potentially eradicate the necessity for Russia to rely on importing such molds copper plates.

Experimental Study On The Use Of Strapping Band Variation As A Substitute For Steel Reinforcement In The Manufacture Of Precast Foundation For Coastal Construction

A solid foundation is a concrete mix using steel reinforcement, but the reinforcement has the disadvantage of being corrosive when used in coastal areas. Therefore, this research uses strapping bands as a substitute for steel reinforcement. This research is focused on the manufacture of mortar plates for lightweight construction, especially in foundation parts such as footing foundations. This research used 5 (five) variations of slab mixture including, variation A1 which is mortar slab without additional strapping band, variation B1 which is mortar slab with additional 3 pieces of strapping band as thick as 1 layer on each top and bottom layer, so on up to variation B4 as thick as 4 layers. The results of the mortar plate bending test obtained the value of the bending moment of variations A1, B1, B2, B3, and B4 are 0.148 kN.m; 0.183 kN.m; 0.222 kN.m; 0.278 kN.m; 0.325 kN.m. Then the maximum bending moment value is averaged in the variation that uses a 4-layer thick strapping band. From this research it can be concluded that to get a high bending moment value, the more strapping bands are used.

Design, manufacturing and thermal analysis of a honeycomb-inspired PCM-filled cold plate

In recent times, electric vehicles (EVs) have been seen as an environment-friendly alternative to conventional vehicles. Lithium-ion battery packs power the EVs today due to their low self-discharge and higher efficiency as compared to the other battery chemistries. These batteries operate in an optimal temperature range. This calls for effective thermal management of these battery packs. Cold plates are a viable method for the thermal management of these packs. An active method of thermal management uses a coolant flowing through the cold plates, maintaining the battery pack temperature. Another approach to cold plate design is the use of Phase Change Materials (PCMs) as a passive cooling method. This paper suggests possible designs for the cooling plates, one using an active method of cooling and the other based on a PCM. The design considerations, thermal performance and manufacturing methods for both are discussed and analyzed. Results show that the PCM-based cold plate maintains the temperature with a very low thermal gradient for relatively shorter discharge durations, whereas the coolant flow-based cold plate shows a better performance for longer discharge durations. Finally, a 3-stage manufacturing process involving - Blanking, Indenting, and Projection Welding has been proposed to manufacture the two types of cold plates.