Rod Production Research Articles

Selected Problems of the Microstructure Evolution During Microalloyed Steel Wire Rod Production Process

AbstractIn the present study, we have discussed the selected problems of microstructure development during the whole manufacturing process, i.e. continuous casting, thermomechanical processing, and cold metal forming of the microalloyed steels wires. In the investigated steels, the microstructure development was controlled by the history of deformation and by the effects of microalloying elements, mostly Nb, Ti, and B. It has been concluded that obtained in the ultrafine grained microalloyed steel wires mechanical properties were first of all resulting from specific structural composition and grain refinement. Additionally, it has been proven that austenite grain refinement, that increases nucleation rate during the austenite-to-ferrite phase transformation, as a result of the thermomechanical processing, are very beneficial from point of view of the final mechanical properties. This problem starts to be very important when the microalloyed steel products are subjected to severe plastic deformation, as it has been shown discussed in the present work for combined processes of wire drawing and wire flattening.

Model Approaches for Simulation of Processes in Rod and Wire Production

Actual improvements in rod or wire production e.g. in relation to power requirements, energy consumption and final material properties demand powerful simulation tools for process optimization, pre-setting calculations or automation. The groove pass design model of TU Bergakademie Freiberg was developed and applied for this purposes. This paper gives a short review of the history of this model approaches and highlights some important stages of development.

Advanced Possibilities of Fast Quality Check in Wire Production Processes by Means of Fast Microstructure Analysis

A new method for a fast analysis of heavily deformed, multicomponent ferritic/pearlitic steels microstructure based on XRD measurements had been developed. Its practical application has been examined and proven during wire rod production of a high-strength eutectoid non-alloyed steel grade containing 0.81 weight percent carbon. For individual technological conditions, the lattice strains and their anisotropy were analysed quantitatively by means of fast X-ray diffraction measurements and correlated with the results of comprehensive mechanical testing. Obtained relationships between the microstructure characteristics and mechanical properties were described using physically based models and used to establish a material specific database for prediction of the mechanical properties from X-ray diffraction data. Depending on the deformation state different parameters have to be applied for the material’s macroscopic properties prediction. Additionally, the fast microstructure analysis can provide more detailed information in the case of deviations from the as-required material’s properties due to technological aberrations.

Сравнительный анализ результатов физического моделирования процесса прокатки прутков из стали 30MnB4 при испытании на кручение и на сжатие

Сравнительный анализ результатов физического моделирования процесса прокатки прутков из стали 30MnB4 при испытании на кручение и на сжатие

Analysis of the Requirements of the Wire Rod Production Standards in Ukraine

It is observed the dynamic of changes in the requirements of national and international standards for production of wire rod. It is shown that the general trend in changing of requirements is not a tightening of technical parameters but in some cases the extension of the range of variation of parameters, which provides the wide opportunities for producers.

Analysis of the Requirements of the Wire Rod Production Standards in Ukraine

It is observed the dynamic of changes in the requirements of national and international standards for production of wire rod. It is shown that the general trend in changing of requirements is not a tightening of technical parameters but in some cases the extension of the range of variation of parameters, which provides the wide opportunities for producers.

The Sucker Rod Pump Parameters Optimization of Horizontal Wells with ASP Flooding Considering the Influence of Centralizers

The centralizers can add the polished rod load, and affect the pumping system efficiency. A pumping system efficiency model has been built by considering the influence of centralizers on polished rod load. The influence of centralizers, stroke length, pumping speed and flooding period on sucker rod pumping system efficiency and production has been studied. The results indicate that the sucker rod pumping system efficiency and production rate decrease while the number of centralizer increases, but the influence of number of centralizer on sucker rod pumping system efficiency and production rate is not big while the influence of stroke length and pumping speed is significant. The sucker rod pumping system efficiency first increase obviously and then trend to be gentle with the stroke length and pumping speed increasing. The pumping system efficiency in main slug of ASP flooding is lowest. The optimization value of stroke length and pumping speed has been selected to maximize the pumping system efficiency. And hence get the reasonable pump depth, and system efficiency, it have reference significance to the reasonable production.

РАСШИРЯЕМЫЙ САМОБЛОКИРУЮЩИЙСЯ ИНТРАМЕДУЛЛЯРНЫЙ СТЕРЖЕНЬ ОСТЕОСИНТЕЗА

The application of extensible rods while carrying out the intramedullary osteosynthesis minimizes surgical intervention and secures high level of operation and minimum time for the patient’s rehabilitation. Nowadays, medical practice uses the extensible Fixion rod (Israel), which is a circular tube with a guiding and a nipple handipieces and four strengthening ribs. The risk of guiding handipiece damage caused by the peculiarities of its structure, high probability of the bone soft tissue traumas due to the complex kinematics of the ribs movement during the rod usage and high ex-works price limit the application of this rod. Creation of the design eliminating all the above disadvantages is relevant for modern medical industry.The paper describes the extensible intramedullary rod developed in Togliatti State University in cooperation with Samara State Medical University and the Clinical Hospital №5 of the city of Togliatti.The rod is a trigonous tube with three welded on strengthening ribs, guiding and nipple handipieces. Before emplacement into the intramedullary (marrowy) canal, the rod is constricted. During the emplacement process, when NaCl solution is being delivered to the rod intracavity under pressure, the rod expands up to its operative condition. A rigid biomechanical system is being formed due to the support of external (contact) surfaces of the ribs as to the mating surfaces of the bone.The developed rod is secured by the patents and has a number of advantages determined by the structure and proved experimentally. The weight of this rod is on an average 10-15% less than its analogue of the same typical size. The progressive motion of the ribs during the rod expansion process promotes intramedullary tissue minimum traumatization of intramedullary tissue. The risk of guiding handipiece damage is eliminated due to its integral design. The reduction of the number of ribs has caused the reduction of welding seams length and the considerable reduction of the rod production cost.

Rod debitage by extraction: An overview of different cases identified for the Upper Palaeolithic and the Mesolithic in Europe

One of the objectives of the CNRS European Research Group GDRE PREHISTOS is to look for cases of “debitage by extraction” on the European continent from the Paleolithic to the First Iron Age. We will thus be able to fill the gaps in our knowledge by first describing each case in technical and economic terms and by identifying new variants of this method. The rod production by extraction is a major invention in the working of osseous materials and it is conceptually similar to the laminar debitage procedure in stone working in that it allows blanks of a similar shape, artificial and standardized, to be produced. The “baguette”, whose shape is close to that of blades, is the best known of these types of blanks. This capacity to produce series of blanks with a sometimes exactly similar morphology and then finished objects led to the standardized mass productions that characterize the evolution of some categories of objects, such as projectile points. This debitage by extraction appears globally during the first half of the Upper Paleolithic (being present in the Early Gravettian of Western Europe). The aim of this paper is to give an overview of different cases identified in the last years for the Upper Paleolithic to the Mesolithic, especially in Europe.

Unsupervised classification of surface defects in wire rod production obtained by eddy current sensors.

An unsupervised approach to classify surface defects in wire rod manufacturing is developed in this paper. The defects are extracted from an eddy current signal and classified using a clustering technique that uses the dynamic time warping distance as the dissimilarity measure. The new approach has been successfully tested using industrial data. It is shown that it outperforms other classification alternatives, such as the modified Fourier descriptors.

Online Real-Time Detection Scheme Research on Precision of Filter Rod Circumference

Precision of filter rod circumference is an important performance index of the cigarette manufacturing. The forming mechanism of filter rod, equipment vibration and other interference factors all lead to fluctuations of precision of filter rod circumference which can affect the precision of the cigarette. The existing KDF2/3 filter rod making machine which has the characteristics of compact structure (small space dimension), high speed (300 m/min) and discrete control of precision of filter rod circumference is the core equipment of filter rod production. This paper puts forward four kinds of online real-time detection schemes on precision of filter rod circumference which are Aomeijia’s many groups of detectors scheme, Keyence’s contour detection scheme, high precision measuring diameter instrument detection scheme using multiple sets of KD series meter and the 360 degrees rotating survey meter. On the basis of extensive analysis and experimental validation, Aomeijia’s four-way diameter measuring instrument scheme is optimal. The scheme applies laser to non-contact high speed scan on key radial diameter size of filter rod which achieves 0.001mm high precision detection.

Development of On-Line Monitoring System for Large Rotating Machinery under Complex Circumstance

Large rotating machinery is widely used in industrial production process. With the computer network technology, system testing technology, signal analysis and fault diagnosis technology, large motor based on high speed wire rod production line as the object, the online monitoring method of large motor is present. Based on it, the signal processing approach of large motor under complex circumstance is proposed, and the software of on-line monitoring system for large motor is developed. Through monitoring the key parameters of the distributed signals of temperature, pressure, current and so on, the developed system can accurately analyze and locate critical faults of equipments, reduce faults rate, extend the service life and increase productivity of the motor equipment.

Design of a PLC-Based Automatic Separate Channel Filter Rod Sampling Detection System

DF10 filter rod forming machine produced by Italy GD Automatic Machinery Ltd is the world's fastest filter rod maker adopting the design of dual-channel. To achieve automatic sampling detection on line, a PLC-based automatic separate channel filter rod sampling detection system has been designed. Mainly composed of a sampling and launching device, matching tube, receiving device, a test instruments, PLC control unit and data terminal, the system first samples the filter rods from the two channels, then launches them into the test instrument to measure their physical parameters, and after wards send the real-time feedback of testing data to the data terminal. The application results show that the system has the advantages of convenient operation, high stability, safety and reliability. With an effective batch’s completion rate above 98%, it greatly reduces the labor intensity of operators and QC personnel, and significantly improves the quality control capacity of filter rod production.

System modeling and temperature control of reheating furnace walking hearth type in the setting up process

Reheating furnace walking hearth type (RFWHT) has been used for the iron and wire rods of the reheating process in Ratchasima Steel Products Co., Ltd. Factory (Nakhon Ratchasima, Thailand). Ratchasima Steel Products Co., Ltd. is among the companies with the highest energy consumption in Thailand. The company is confronted by problems related to performance improvement in terms of temperature control and reduction of fuel consumption. Since the reheating furnace was installed in 1964 and with the adjustment of some of its devices, the system has required an optimal controller for controlling the temperature inside each zone of the reheating furnace. This study aimed at investigating the mathematical model from the experimental data in the manufacturing process of rolling wire rod production and subsystem by using system identification with genetic algorithm. Results can be used to design a proportional-integral controller for temperature control in each zone and to reduce fuel.

Research on Workshop Layout Based on SLP and Witness

In the paper, the connecting rod production line in one workshop is taken as the research object. The workshop layout is designed by SLP algorithm. The specific work includes dividing the operating units, quantifying logistics relations and non-logistics relations, determining the importance of proportion and the integrated relationship of activities that based on the actual situation of the workshop, and then getting the plan finally. The Witness simulation is applied to simulate the theoretical analysis results and imitate the production logistics situation of the factory. Finally, the optimization scheme is determined by the comparison of several schemes in the aspects of logistics and the number of back flow.

Connecting Rod Machining Process Improvement

connecting rod parts except under larger dynamic load in the institutions, it is also connected with other parts, movement and direction, therefore, the part of the connecting rod connected with other parts on the machining accuracy is crucial. In this paper, analysis and study connecting rod machining process, through the improvement plan, ensure the accuracy of the important parts of the connecting rod parts and the connecting rod production and processing efficiency.

Prediction of Mechanical Properties of Carbon Steels After Hot and Cold Forming by Means of Fast Microstructure Analysis

A new method for fast microstructure analysis of heavily deformed ferritic–pearlitic (F–P) steels has been developed based on X‐ray diffraction (XRD). The method provides information about residual stresses and microstructure defects occurring within the material volume and therefore allows reliable estimation of strength properties. Besides, significant reduction of testing time can be achieved compared to conventional investigation methods. Development and testing of “fast microstructure analysis” was done by means of experimental simulation of wire and rod production process including hot rolling, wire drawing, and heat treatment of steel C45 with ferrite/pearlite microstructure. It was found that the dominant structure defects driving the ultimate tensile strength of F–P steel in case of hot‐rolled and heated steel are the misfit dislocations in pearlite, while in the cold‐drawn wires, it is the residual stress borne by the cementite lamellas.

Void Closure Behavior in Large Diameter Steel Rod during H-V Rolling Process

In order to reveal the mechanism and condition of void closure in large diameter steel rod during horizontal-vertical (H-V) groove rolling process, a three-dimensional thermomcchanically coupled finite element model was established for 9-stand H-V groove rolling process aiming at a ϕ 150 mm steel rod production line. A spherical hole with diameter from 2 to 10 mm was preset into the center of continuous casting billet with a rectangle cross section of 300 mm×360 mm in this model to simulate the void defect, and then finite element analyses were carried out to observe and quantify the void shape evolution in each pass on the three orthogonal coordinate plane sections. The results showed that the void was formed roughly in the reduction and extension directions, and crushed gradually from spherical shape to an approximate ellipsoid, micro-crack and finally to be closed. A quantitative analysis was carried out by using elliptic radii and closure ratio to describe this evolution process; it indicated that the longest axis of the ellipsoid coincided with the rolling line, and the second and third axes were alternatively horizontal and vertical on the exit cross section according to change of the reduction direction in H-V groove. The void closure behavior during H-V rolling was more complicated than that of common horizontal rolling, and the influence of groove type and the extension coefficient on the void closure ratio was presented. Finally, a pilot rolling experiment was performed on a 5-stand H-V experimental mill to verify the numerical simulation results, and the experimental results are in good agreement with the numerical simulation results.

Hailat Araka and the South Arabian Neolithic

A small Neolithic lithic scatter site was discovered in 1992 through survey in the southern region of Dhofar, Oman just south of the Rub al Khali. Four test units (1994, 2009) confirmed a 60–90 cm single period Neolithic stratification sequence of the mid‐sixth millennium BC. Lithic debris contains all stages of knapping from prepared cores and is dominated by trihedral rod production. Based on comparable sites both to the west in Yemen and to the east in northern Oman/the UAE, it is suggested that still rare domesticated cattle and ovicaprids supplemented a basic forager lifestyle. Participation in long‐range trade networks involved marine shells, exotic flint tools as well as obsidian, steatite and amazonite. Genetic testing suggests that the Neolithic populations may represent ancestral Modern South Arabic Language (MSAL) populations currently living in southern Arabia.

Quantifying the Activity of <em>cis</em>-Regulatory Elements in the Mouse Retina by Explant Electroporation

Transcription factors within cellular gene networks control the spatiotemporal pattern and levels of expression of their target genes by binding to cis-regulatory elements (CREs), short (˜300-600 bp) stretches of genomic DNA which can lie upstream, downstream, or within the introns of the genes they control. CREs (i.e., enhancers/promoters) typically consist of multiple clustered binding sites for both transcriptional activators and repressors(1-3). They serve as logical integrators of transcriptional input giving a unitary output in the form of spatiotemporally precise and quantitatively exact promoter activity. Most studies of mammalian cis-regulation to date have relied on mouse transgenesis as a means of assaying the enhancer function of CREs(4-5). This technique is time-consuming, costly and, on account of insertion site effects, largely non-quantitative. On the other hand, quantitative assays for mammalian CRE function have been developed in tissue culture systems (e.g., dual luciferase assays), but the in vivo relevance of these results is often uncertain. Electroporation offers an excellent alternative to traditional mouse transgenesis in that it permits both spatiotemporal and quantitative assessment of cis-regulatory activity in living mammalian tissue. This technique has been particularly useful in the analysis of cis-regulation in the central nervous system, especially in the cerebral cortex and the retina(6-8). While mouse retinal electroporation, both in vivo and ex vivo, has been developed and extensively described by Matsuda and Cepko(6-7,9), we have recently developed a simple approach to quantify the activity of photoreceptor-specific CREs in electroporated mouse retinas(10). Given that the amount of DNA that is introduced into the retina by electroporation can vary from experiment to experiment, it is necessary to include a co-electroporated 'loading control' in all experiments. In this respect, the technique is very similar to the dual luciferase assay used to quantify promoter activity in cultured cells. When assaying photoreceptor cis-regulatory activity, electroporation is usually performed in newborn mice (postnatal day 0, P0) which is the time of peak rod production(11-12). Once retinal cell types become post-mitotic, electroporation is much less efficient. Given the high rate of rod birth in newborn mice and the fact that rods constitute more than 70% of the cells in the adult mouse retina, the majority of cells that are electroporated at P0 are rods. For this reason, rod photoreceptors are the easiest retinal cell type to study via electroporation. The technique we describe here is primarily useful for quantifying the activity of photoreceptor CREs.