Rolling Pressure Research Articles

Perancangan Alat Cetak Pelet Ayam Portabel Guna Mengurangi Biaya Pembelian Pakan (Studi KAsus: Peternakan Pak Musraji)

The design of a pellet molding tool is a solution to reduce the burden of broiler feed production and reduce the cost of purchasing feed. In this design I innovated a portable chicken pellet molding tool that can be used without having to have an electrical outlet nearby. The working principle of this pellet molding tool is sequentially when the electric motor is turned on, the feed raw material mixture is fed into the funnel, the engine power will be distributed to the axle screw via a v-belt transmission by moving the roller press which functions to stir the pellet raw material. Pellet raw materials that have been thoroughly mixed will fall down to the end of the output funnel. The pellet raw material mixture will come out through the hole screen to form pellets. The results of the trial of a chicken pellet press with a 5Kw motor can produce 100 kg/hour of chicken pellets and a cost efficiency of IDR 25,920,000/month is also obtained.

Wear Behaviors of the Surface of Duplex Cast Steel after the Burnishing Process.

Duplex steel and cast steels have a wide range of applications in many industrial sectors, for example, oil extraction, printing, petrochemical industry, energy-exhaust gases desulphurization systems, seawater desalination plants, and the shipbuilding industry. The machine elements can be produced with different techniques, which determine the operational properties. A material with the same chemical composition made as a casting will have worse mechanical properties than, for example, a forged element. This depends on the microstructure, its fragmentation and its morphology. However, the costs of casting are lower than, for example, forging, and, in addition, not all shapes obtainable in the casting process can be made using metal-plastic working methods. This article presents research results concerning the influence of the burnishing process on the properties of the duplex cast steel surface layer. The purpose of the research was to verify the impact of static pressure roller burnishing (SPRB) parameters on the wear of the surface layer of duplex cast steel. The subject of the research was cast steel in the GX2CrNiMoN22-5-3 grade-according to PN-EN 10283:2019-that was burnished using 15 variants of technological parameters. Then, the samples were subjected to surface wear tests using the INSTRON 8874 device. On the basis of the observed wear appearances, the acting wear mechanisms are defined and evaluated according their contribution to the wear behavior. Detailed information about the wear phenomena will help industries to minimize their maintenance losses related to surface wear. The possibility of shaping surface properties by mechanical burnishing is part of the current direction of surface engineering development. This technology, combined with a high-potential material such as duplex cast steel, makes it possible to increase wear resistance.

Processing and characterisation of hot rolling pressed PVDF films with enhanced field-induced polarisation

Poly (vinylidene fluoride) (PVDF) based polymers are good candidates for high-power energy storage in dielectric capacitors. So far, most studies reporting PVDF with high energy density are based on solution casting, a method ill-suited for large-scale production. In this work, we develop PVDF films with high crystallinity (47%) and ultrahigh β-phase (∼97%) using Hot Rolling Press (HRP). During HRP, the crystallinity, fraction of β-phase, internal stress, and the piezoelectric coefficient d33 increased with rolling temperature. The anisotropic stress imposed by two rollers led to a highly preferred orientation of the HRP film along the rolling direction. Notably, the HRP film exhibits an enhanced field-induced polarisation Pin-max value (0.16 C m−2) compared to conventional PVDF films (0.10 C m−2), with an energy density of 32.6 J cm−3 at 871 kV mm-1. The good low field dielectric (εr ∼19 @ 1 kHz) and piezoelectric (d33 ∼30 pC N-1) properties with high-temperature stability (up to 100 °C), and its suitability for in-line continuous production, make HRP PVDF films promising for low field dielectric and piezoelectric applications.

In-situ infrared annealing for laser-assisted automated fiber placement to enhance interlaminar properties without sacrificing laydown efficiency

Laser-assisted automated fiber placement (LAFP) in-situ consolidation (ISC) of thermoplastic composites suffers from poor interlaminar bonding. Repass treatment improves interlaminar bonding but sacrifices laydown efficiency. Here we propose an in-situ infrared annealing (IIA) strategy that combines infrared heat treatment with a second pressure roller immediately following the LAFP ISC process. This approach causes repeated interlaminar melting and slower cooling, reducing the porosity by 57.9% and increasing crystallinity by 89.2% compared to LAFP-manufactured carbon fiber-reinforced polyether-ether-ketone composites. Moreover, it completes the crystallization process with only a single placement rather than multiple placements by repass treatment. Interlaminar shear strength and mode I interlaminar fracture toughness are improved by 239.7% and 292.4%, respectively. These improvements are comparable to those achieved by repass treatment with a near-infrared laser. Overall, the IIA strategy offers a promising alternative to traditional post-consolidation processes while maintaining laydown efficiency.

Effects of Pressure Rollers with Variable Compliance in the Microfinishing Process Utilizing Abrasive Films.

This article presents a comprehensive investigation into pressure rollers utilized in the microfinishing process, covering aspects such as design, experimental properties, compliance, and finite element simulation. Prototype pressure rollers with unconventional elastomer configurations were designed and analyzed to explore their effectiveness in achieving superior surface finishes. Experimental analysis and finite element simulations were conducted to gain insights into the performance and behavior of these pressure rollers under various loading conditions. This study addresses the validation of constitutive material models used in finite element simulations to ensure accuracy and reliability. The results indicate that the applied material model, validated through experimental analysis, accurately predicts pressure roller behavior. Finite element simulations reveal distinct contact zone patterns and stress distributions across the contact surfaces, highlighting the importance of considering deflection-induced variations in contact behavior. Additionally, the investigation evaluates the effectiveness of different pressure rollers in removing surface irregularities during the microfinishing process. Roller R3 demonstrates the highest efficacy in removing surface peaks, suggesting its potential for achieving superior surface finishes. Overall, this research contributes to the advancement of microfinishing techniques by providing insights into pressure roller design, performance, and behavior, thereby optimizing microfinishing processes to produce high-quality components. The urgency of this study arises from the growing need for exceptional surface finishes in various industrial sectors. With manufacturing industries increasingly pursuing high-precision components boasting flawless surface quality, the significance of microfinishing processes is highlighted.

Enhancing surface integrity in friction stir welding through deep rolling and post-weld heat treatment

This study aimed to investigate mechanical surface treatment through deep rolling (DR) and post-weld heat treatment (PWHT) to enhance the surface integrity of an AA7075-T651 aluminum alloy welded through friction stir welding (FSW). The surface integrity of the welded joint was evaluated by analyzing residual stress, microhardness, surface roughness, microstructure, and fatigue life. The experimental design comprised three sets: one set exclusively applied FSW, another set applied FSW followed by DR (FSW-DR), and the last set applied FSW followed by PWHT (FSW-PWHT). Fatigue testing (screening) was performed through a four-point bending test with a bending stress of approximately 300 MPa, test frequency of 2.5 Hz at room temperature, and stress ratio (R) of 0. The FSW parameters included a tool rotational speed of 1600 rpm, welding speed of 30 mm/min, immersion depth of 0.1 mm, dwell time of 15 s, and tool tilt angle of 0°. The DR parameters included a rolling pressure of 150 bar and rolling speed of 1400 mm/min. The results revealed that the residual stress significantly influenced fatigue life. The fatigue test demonstrated that FSW workpieces treated with the DR process (FSW-DR) exhibited the highest fatigue life, showing a remarkable increase of 33.5 % compared with that of untreated FSW workpieces. Moreover, the residual stress changed from tensile to compressive, accompanied by noticeable enhancements in microhardness and surface roughness. These results highlight that FSW followed by the DR process (FSW-DR) positively affects weld surface integrity, resulting in an extended service life for welded components.

Critical Assessment of Novel Developments in HPGR Technology Using DEM.

Advances in high-pressure grinding roll (HGPR) technology since its first commercial application in the cement industry include new roll wear protection techniques and new confinement systems. The latter contribute to reductions in the edge effects in an attempt to reach a more homogenous product size along the rolls. Additional advances in this technology have been made in recent years, while modeling and simulation tools are also reaching maturity and can now be used to subject such novel developments to detailed scrutiny. This work applies a hybrid approach combining advanced simulations using the discrete element method, the particle replacement model and multibody dynamics to a phenomenological population balance model to critically assess two recent advances in HPGR technology: spring-loaded cheek plates and the offset roller press. Force and torque controllers, included in the EDEM 2022.1 software, were used to describe the responses of the geometries in contact with the granular material processed. Simulations showed that while the former successfully reduced the lateral bypass of the material by as much as 65% when cheek plates became severely worn, the latter demonstrated lower throughput and higher potential wear but an ability to generate a finer product than the traditional design.

THREE-DIMENSIONAL MODEL OF EQUIVALENT ROLL GAP OF CVC MILL UNDER CONDITIONS OF ROLL CROSSING AND NO LOAD

Traditional roll technologies focus solely on the contour of the roll gap at the outlet under ideal conditions. However, upon roll crossing, the three-dimensional distribution of the deformation zone becomes asymmetrical, leading to an adverse impact on the rolling pressure in the deformation zone. To study the screw-down load deviation of plate mills, it is necessary to accurately calculate the equivalent three-dimensional roll gap in the deformation zone under roll-crossing conditions. In this paper a model for calculating the equivalent three-dimensional roll gap under the conditions of roll crossing and no load was established based on the method of the coordinate nonlinear transformation of the spatial rectangular coordinate system. Based on this model, the influences of roll-crossing angles and translation parameters on the symmetry of the equivalent three-dimensional roll gap were analyzed. The distribution of the three-dimensional equivalent roll gap was calculated with different roll lengths, roll radii, and the roll gap’s nominal thickness. The intuitive contour map reveals that under the same condition of crossing angle and translation parameters, the larger the roll length and roll radii and the smaller the roll gap’s nominal thickness are, the greater the influence of the roll crossing on the asymmetrical distribution of roll gap is. It put forward a quantitative calculation method for evaluating the symmetrical distribution of the roll gap, and the calculation results can provide the equivalent roll profile for the roll-deformation model.

The influence of zinc oxide-silicate composites on the aging resistance of asphalt

Asphalt binder is susceptible to aging from heat, air and sunlight exposure during service, leading to pavement distresses. This study aimed to improve the aging resistance of asphalt using zinc oxide-silicate (ZOS) composites. ZOS containing 2–8 wt% ZnO were synthesized via a one-step sol-gel method and incorporated into an unmodified 70/100 penetration grade asphalt binder. The rheological properties and aging characteristics were evaluated before and after rolling thin film oven and pressure aging vessel protocols. Dynamic shear rheometry showed increased complex modulus and decreased phase angle for ZOS-modified binders, indicating improved rutting resistance. Aging indices revealed the 6% ZOS composite had the least susceptibility to oxidative aging. FTIR analysis confirmed the formation of carbonyl and sulfoxide functional groups during aging, which were mitigated by ZOS addition. Scanning electron microscopy visualized nano-scaled ZnO particles dispersed within the silica matrix and asphalt binder. The ZOS composites delayed the aging rate through physicochemical interactions between ZnO and the asphalt medium. An optimum ZOS dosage of 4–6% was found to enhance the anti-aging properties. The renewable silica-supported ZnO composites show potential as cost-effective modifiers for improving asphalt durability.

Enhancing the Longitudinal Compressive Strength of Freeform 3D-Printed Continuous Carbon Fiber-Reinforced Polymer Composite Laminate Using Magnetic Compaction Force and Nanofiber Z-Threads.

Low fiber-direction compressive strength is a well-recognized weakness of carbon fiber-reinforced polymer (CFRP) composites. When a CFRP is produced using 3D printing, the compressive strength is further degraded. To solve this issue, in this paper, a novel magnetic compaction force-assisted additive manufacturing (MCFA-AM) method is used to print CFRP laminates reinforced with carbon nanofiber (CNF) z-threads (i.e., ZT-CFRP). MCFA-AM utilizes a magnetic force to simultaneously levitate, deposit, and compact fast-curing CFRP prepregs in free space and quickly solidifies the CFRP laminate part without any mold nor supporting substrate plate; it effectively reduces the voids. The longitudinal compressive test was performed on five different sample types. ZT-CFRP/MCFA-AM samples were printed under two different magnetic compaction rolling pressures, i.e., 0.5 bar and 0.78 bar. Compared with the longitudinal compressive strength of a typical CFRP manufactured by the traditional out-of-autoclave-vacuum-bag-only (OOA-VBO) molding process at the steady-state pressure of 0.82 bar, the ZT-CFRP/MCFA-AM samples showed either comparable results (by -1.00% difference) or enhanced results (+7.42% improvement) by using 0.5 bar or 0.78 bar magnetic rolling pressures, respectively.

Microgrid-Patterned Ni Foams as Current Collectors for Ultrafast Energy Storage Devices

Current research is focused on developing active materials through surface functionalization, porosity, composites, and doping for ultrafast electric double layer capacitors (EDLCs). In this study, deviating from existing strategies focused on active materials, we designed tunable 3D microgrid-patterned (MP) surface morphologies on Ni foams used as current collectors using SUS meshes as rigid stamps during roll pressing. The surface geometries of the MP-Ni foams were controlled to standard mesh scales of 24, 40, and 60 (denoted as 24MP-Ni, 40MP-Ni, and 60MP-Ni, respectively). The three MP-Ni samples with different microgrid sizes presented different surface geometries, such as root-mean-square roughness (Rrms), skewness roughness (Rsk), and width/depth scales of the microgrid patterns. Consequently, 40MP-Ni demonstrated an optimized surface geometry with high Rrms (35.4 μm) and Rsk (−0.19) values, which facilitated deep slurry infiltration and increased its contact area with the active material. Surface optimization of the MP-Ni enabled ultrafast and reversible charge transport kinetics owing to its relaxed electron transfer resistance and robust adhesion to the active material compared with bare Ni foam. EDLC electrodes with 40MP-Ni achieved an ultrafast-rate capability (96.0 F/g at 20 A/g) and ultrafast longevity (101.9% capacity retention after 5000 cycles at 5 A/g) without specific modification of active material.

The Influence of Machining Conditions on the Orientation of Nanocrystallites and Anisotropy of Physical and Mechanical Properties of Flexible Graphite Foils.

The physical and mechanical properties and structural condition of flexible graphite foils produced by processing natural graphite with nitric acid, hydrolysis, thermal expansion of graphite and subsequent rolling were studied. The processes of obtaining materials and changing their characteristics has been thoroughly described and demonstrated. The structural transformations of graphite in the manufacture of foils were studied by X-ray diffraction analysis (XRD) and transmission electron microscopy (TEM). A decrease in the average size of the coherent scattering regions (CSR) of nanocrystallites was revealed during the transition from natural graphite to thermally expanded graphite from 57.3 nm to 20.5 nm at a temperature of 900 °C. The rolling pressure ranged from 0.05 MPa to 72.5 MPa. The thickness of the flexible graphite foils varied from 0.11 mm to 0.75 mm, the density-from 0.70 to 1.75 g/cm3. It was shown that with an increase in density within these limits, the compressibility of the graphite foil decreased from 65% to 9%, the recoverability increased from 5% to 60%, and the resiliency decreased from 10% to 6%, which is explained by the structural features of nanocrystallites. The properties' anisotropy of graphite foils was studied. The tensile strength increased with increasing density from 3.0 MPa (ρ = 0.7 g/cm3) to 14.0 MPa (ρ = 1.75 g/cm3) both in the rolling direction L and across T. At the same time, the anisotropy of physical and mechanical properties increased with an increase in density along L and T to 12% with absolute values of 14.0 MPa against 12.5 MPa at a thickness of 200 μm. Expressed anisotropy was observed along L and T when studying the misorientation angles of nanocrystallites: at ρ = 0.7 g/cm3, it was from 13.4° to 14.4° (up to 5% at the same thickness); at ρ = 1.3 g/cm3-from 11.0° to 12.8° (up to 7%); at ρ = 1.75 g/cm3-from 10.9° to 12.4° (up to 11%). It was found that in graphite foils, there was an increase in the coherent scattering regions in nanocrystallites with an increase in density from 24.8 nm to 49.6 nm. The observed effect can be explained by the coagulation of nanocrystallites by enhancing the Van der Waals interaction between the surface planes of coaxial nanocrystallites, which is accompanied by an increase in microstrains. The results obtained can help discover the mechanism of deformation of porous graphite foils. The obtained results can help discover the deformation mechanism of porous graphite foils. We assume that this will help predict the material behavior under industrial operating conditions of products based flexible graphite foils.

Study on the change rule of low-temperature properties of asphalt binder with aging time

ABSTRACT Low-temperature cracking is common distress in asphalt pavements. Understanding the change rule of its low-temperature properties is helpful in investigating the optimal maintenance timing of asphalt pavement. In this paper, the change rule of low-temperature properties of asphalt binders with aging time is investigated by various indexes. Four asphalt binders and four anti-aging modified asphalt binders were subjected to the rolling thin film oven (RTFO) test and pressure aging vessel (PAV) test. Dynamic Shear Rheometer (DSR) with the 4 mm parallel plates was used to determine the low-temperature properties of asphalt binders. The results show that aging and low temperature have a negative impact on the low-temperature properties of asphalt binders. The anti-aging agent improves the low-temperature properties and aging resistance of asphalt binders. Compared with other indexes, the critical cracking temperature Tc and the critical temperature difference ΔTc are more suitable for analysing the effect of aging on the low-temperature properties of asphalt binders. Also, the ΔTc shows the three-stage decreasing rule of ‘fast-slow-fast’, with the inflection points. It meant that the low-temperature properties of asphalt binders had been altered at the inflection points, which provided a favourable reference to research on the optimal maintenance timing of asphalt pavement.

High-Throughput Additive Manufacturing of Continuous Carbon Fiber-Reinforced Plastic by Multifilament.

Additive manufacturing (or 3D printing) of continuous carbon fiber-reinforced plastics with fused deposition modeling is a burgeoning manufacturing method because of its potential as a powerful approach to produce lightweight, high strength and complex parts without the need for a mold. Nevertheless, it cannot manufacture parts rapidly due to low throughput. This paper proposes a high-throughput additive manufacturing of continuous carbon fiber-reinforced plastics by multifilament with reference to fiber tape placement. Three filaments were fed and compaction printed simultaneously by a robotic manufacturing system. The coupled thermal-mechanical model of the filament deformation during printing was developed to eliminate the initial interval between the filaments and improved mechanical properties. Furthermore, the mathematical relationship between filament deformation and printing parameters consisting of printing temperature, printing speed and roller pressure was proposed using response surface methodology with the line width as the response. The tensile tests demonstrate that the tensile properties of printed parts are positively correlated with the line width, but not infinitely improved. The maximum tensile strength and tensile modulus are 503.4 MPa and 83.11 Gpa, respectively, which are better than those obtained by traditional methods. Void fraction and scanning electron microscope images also reveal that the appropriate line width achieved by the reasonable printing parameters contributes to the high-throughput multifilament additive manufacturing of continuous carbon fiber-reinforced plastics. The comparison results indicate that the high-throughput multifilament additive manufacturing proposed in this paper can effectively improve the speed of continuous carbon fiber-reinforced plastics additive manufacturing without degrading the mechanical performance.

Comparative analysis of FEM tire-soft snow interaction and theoretical model based on Bekker’s coefficients

Tire-deformable terrain interaction is a complex phenomenon that has proven difficult to characterize accurately and comprehensively using numerical models. While researchers have attempted to develop various numerical models to estimate tire behavior on deformable terrain, the most accurate models to date rely on empirical data and are only applicable to specific rolling conditions. In this research paper, a comparison between theoretical mechanics and a finite element method (FEM) model of a rigid tire rolling on a layer of soft snow is presented. The goal is to compare the data obtained from the FEM tire-soft snow interaction analysis with the data generated by a theoretical numerical model. The FEM snow model is developed using the Drucker-Prager cap material model while the tire is assumed rigid. The assumption of the rigid tire can provide reasonably accurate results in the case of the soft snow interaction model. The theoretical pressure-sinkage coefficients of the Bekker equation (kc, kϕ and n) for soft snow are calculated by simulating vertical penetration tests in the FEM snow model. The results of the pressure distribution and rolling resistance due to compaction obtained by the FEM and the theoretical model results are then compared.

Formation and prevention of turning crack of screw for electronic parking brake system

The cracking of screws made from medium-carbon cold heading steel for the electronic parking brake system was studied through the analysis of the microstructure and the systematic investigation of the whole process, and the corresponding improvement measures were proposed at last. Results showed that the cracks initiated at the root of the threads due to insufficient plasticity generated by the large pressure during thread rolling were the resource of the fracture, which was further extruded during the turning process, while the centering condition was not well. It was necessary to adjust the appropriate parameters of rolling pressure and rolling time to avoid heavy work hardening and also pay attention to the cleanness on the surface of the rolling plate or the wheel.

Determination of Factors Affecting the Quality of Sized Cotton Yarn Using Screening Experimental Method

ABSTRACT This research examines screening of the factors affecting cotton-sized yarn gain strength, elongation, stretch, size pick-up, and yarn abrasion resistance. The factors considered in this research are sizing machine parameters like sizing machine speed, squeezing roller pressure, warp yarn tension of various sizing machine zones, warp yarn twist, and viscosity of the size paste. Taguchi design with Minitab software has been used to design and analyze the results of the experiments. The study revealed that viscosity, yarn twist, sizing machine speed, and wet tension affected sized yarn gain strength significantly. Viscosity has maximum contribution to gain strength (34.57%) compared to other factors and has a positive effect on the gain strength of the sized yarn. For stretch percentage and the loss elongation of sized yarn, the wet tension is the most significant factor with 50.30% and 52.13% contribution respectively. Moreover, for the size pick-up and yarn abrasion resistance of sized yarn, the speed of the sizing machine is the most effective parameter with 44.45% and 56.29% contribution, respectively. The screening experimental result revealed the most significant factor that must be further optimized using response surface methods of experimental design.

Determining the Impact of Roller Compaction Processing Conditions on Granulate and API Properties: Impact of Formulation API Load.

Previous work demonstrated that roller compaction of a 40%w/w theophylline-loaded formulation resulted in granulate consisting of un-compacted fractions which were shown to constitute between 34 and 48%v/v of the granulate dependent on processing conditions. The active pharmaceutical ingredient (API) primary particle size within the un-compacted fraction was also shown to have undergone notable size reduction. The aim of the current work was to test the hypothesis that the observations may be more indicative of the relative compactability of the API due to the formulation being above the percolation threshold. This was done by assessing the impact of varied API loads in the formulation on the non-granulated fraction of the final granulate and the extent of attrition of API particles within the non-granulated fraction. The influence of processing conditions for all formulations was also investigated. The results verify that the observations, both of this study and the previous work, are not a consequence of exceeding the percolation threshold. The volume of un-compacted material within the granulate samples was observed to range between 34.7 and 65.5% depending on the API load and roll pressure, whilst the API attrition was equivalent across all conditions.

Study on roll shape control characteristics of electromagnetic control sleeve support roll

The paper proposed a new type of electromagnetic control support roll to obtain a better ability of controlling the plate shape. According to the principle of induction heating, the bulge shape of the support roll and the contact pressure between the rolls are changed to control the crown of the work roll. To analyze the shape control characteristics of the electromagnetic control sleeve support roll, the roll system model of the four-high mill was established and the no-load bulging experiment was carried out. The simulation results show that under different roll sleeve thickness, current frequency and current intensity, the bulge amount of support roll, contact pressure between rolls and work roll crown increase with heating time, but the growth rate gradually decreases to zero. The bulge of the support roll, the contact pressure between the rolls, the crown of the work roll change quasi-linearly with the current frequency and parabolically with the current intensity. The bulging amount of the support roll and contact pressure decrease with the increase of the thickness of the roll sleeve, and the crown of the work roll increases first and then decreases. This paper verifies the feasibility of adjusting the shape of roll gap by electromagnetic control sleeve support roll, which provides a basis for multi-zone joint control.

Study on modeling roller squeezing semi-finished leather products

This study is devoted to the analysis of moisture content in a two-roll module of a machine for squeezing semi-finished leather products after chrome tanning. An analytical relationship was obtained that describes the patterns of variation in moisture content during the roller pressing of semi-finished leather products; inequalities were derived for estimating the residual moisture content of semi-finished leather products. It was revealed that with a decrease in the thickness and initial moisture content of the semi-finished leather product, its moisture content decreases. It was stated that with an increase in the initial moisture content of the semi-finished leather product, its residual moisture content increases and asymptotically approaches a certain value.