Rolling Speed Research Articles

Optimization of Operation Parameters and Performance Prediction of Paddy Field Grader Based on a GA-BP Neural Network

Paddy field leveling is an essential step before rice transplanting. During the operation of a paddy field grader, a common issue is the wrapping of rice straw around the blades, resulting in a low rice straw burial rate. This study focused on analyzing the operating parameters of a disc spring–tooth-combined paddy field grader. A soil–straw mechanism simulation model was created using EDEM 2021 software to simulate the field operation status. Firstly, the single-factor test was carried out, with the working speed, the working depth of the disc cutter roller, and the rotation speed of the cutter roller as the factors and the straw-buried rate (SBR) and the machine forward resistance (MFR) as the test indexes, and the parameter range was optimized. The parameters were optimized by the response surface method (RSM) and machine learning algorithms. The results indicated that the genetic algorithm–back propagation (GA-BP) neural network outperformed other optimization models in terms of prediction accuracy and stability. By utilizing the GA-BP regression model and RSM model for regression fitting, two sets of optimal parameter combinations were obtained. Verification experiments were carried out using two sets of parameter combinations. Taking the average of the experimental results, the simulation results showed that the straw burial rate was 93.47% and the forward resistance was 6487 N for the parameter combinations of RSM, and the straw burial rate was 94.86% and the forward resistance was 6352 N for the parameter combinations of GA-BP; the field experiments showed that the straw burial rate was 92.86% and the forward resistance was 6518 N for the parameter combinations of RSM, and the straw burial rate was 95.17% and the forward resistance was 6249 N for the parameter combinations of GA-BP. The results demonstrated that the GA-BP prediction model exhibited better predictive capabilities compared to the traditional RSM, providing more accurate predictions of the paddy field grader’s field operation performance.

Preparation of high-strength ZrO2 ceramics by binder jetting additive manufacturing and liquid glass infiltration

Binder jetting (BJ) additive manufacturing of zirconia (ZrO2) ceramics presently encounters the challenges of achieving high relative density, dimensional precision, and superior mechanical properties of the prepared ceramics. This study extensively investigates the impacts of BJ processing parameters—namely, binder saturation, layer thickness, roller speed, and printing layout—on the dimensional accuracy, density, and mechanical strength of the resulting green parts. The identification of optimal BJ processing parameters is pivotal in the fabrication of ZrO2 ceramic green bodies with superior dimensional precision and mechanical strength. The study shows that while solid-phase sintering alone can result in a relative density of 50.99%–54.27 % for BJ-processed ZrO2 ceramics, glass infiltration after sintering substantially elevates the relative density and flexural strength. Specifically, infiltration at an optimal temperature of 800 °C increases the relative density of the sintered ceramic to 94.49 % and flexural strength to 76.48 ± 3.25 MPa, which represent a significant improvement of 40.22 % in density and a 35-fold increase in strength of the sintered ZrO2 ceramics, respectively. These findings underscore the potential of BJ printing and subsequent glass infiltration as a synergistic approach to achieve high-performance ZrO2 ceramics through additive manufacturing.

Extended Kalman filter-based robust roll angle estimation method for spinning vehicles

Attitude measurement is a basic technique for monitoring vehicle motion states and safety. The spin motion of a vehicle couples the attitude angles with each other, which has an impact on the navigation and control of the vehicle. Global navigation satellite system (GNSS) signals-based roll angle measurement methods are important for vehicle attitude measurement. Most of existing studies use continuous signal power, but the case of loop lock loss leading to discontinuous power reception has not been considered. A robust estimation method for the roll angle based on the Tukey weight function is proposed to improve the measurement accuracy in cases of discontinuous reception. The characteristics of the GNSS signals, the geometric relationship between the signal power and roll angle of the vehicle are discussed. By installing a GNSS receiver with a single patched antenna on a rotating platform with a controllable rolling speed, the proposed method was verified by experiments. The robust estimation errors of different weight functions are analyzed. According to the characteristics of the gross measurement errors, a robust estimation method of multisatellite power observations is proposed to obtain a high-precision and stable estimation of the vehicle roll angle. The results show that the proposed algorithm can improve the accuracy of roll angle estimation even with gross measurement errors. As a result of the experiments, the estimation errors of the algorithm are 6.57° at a confidence level of 68 % and 15.49°at the confidence level of 95 %. In contrast, they are 11.38° and 37.31° for the traditional LS method. Moreover, the estimation accuracy of the algorithm is not significantly correlated with the vehicle rotational speed. Therefore, the vehicle roll angle can be estimated with high accuracy under a variety of rotational speeds.

Transition from bouncing to rolling on a horizontal surface

If a ball is incident obliquely on a horizontal surface and is allowed to bounce more than once, then it is likely to bounce many times before it starts rolling along the surface. The number of bounces before rolling commences depends on the initial vertical speed and the normal coefficient of restitution. The transition from bouncing to rolling is examined using a simple theoretical model and is compared with experimental data obtained by filming the process with a video camera. We find that the final rolling speed is proportional to the initial horizontal speed of the ball and depends on the initial ball spin, but is independent of the tangential coefficient of restitution. Representative videos for different balls are included as supplementary material, including a superball thrown with a backspin that creates a back and forth motion. Instructors could use the experiment and/or analysis for an advanced undergraduate lab or use a simplified observational exercise for non-majors.

Iron Removal from Low-Grade Pyrophyllite Ore by Microwave Irradiation and Dry Magnetic Separation

Owing to its unique properties, pyrophyllite is an economical alternative to many minerals in different applications. The presence of iron-bearing minerals in Saudi pyrophyllite hampers its industrial uses. The aim of this study was to examine the removal of iron from Saudi low-grade pyrophyllite ore using two approaches. The first approach involves dry high-intensity magnetic separation, whereas the second approach involves microwave pretreatment of the ore before dry magnetic separation. For the first approach, the studied operating parameters were roll speed; feed rate, field intensity, and feed particle size. For the alternative approach, microwave treatment followed by dry magnetic separation, the microwave irradiation time and the magnetic field intensity were studied. The results show that the combined microwave treatment and dry separation method could provide high-purity pyrophyllite for filler industries. Microwave irradiation for 30 min was optimal to change impurity phases (i.e., pyrite, hematite) into ferromagnetic phases in microwave-treated pyrophyllite samples. At a magnetic field intensity of 2000 Gauss, the 30 min microwave-irradiated pyrophyllite sample achieved an iron recovery of 11.2% in non-magnetic fractions, with a removal efficiency of 89% with an alumina recovery of 91.31%.

The effect of Silver addition and deformation parameters on mechanostructure, biodegradation, antimicrobial and mechanical properties of Zn-based biodegradable alloys.

Although low mechanical properties, Zinc (Zn) alloy systems with Copper (Cu) and Silver (Ag) as alloying elements have strong biocompatibility and biodegradability characteristics. This study examined the effects of rolling parameters and Ag alloying on the mechanical, biodegradable, and final structure of an alloy based on Zn. Comparing treated and untreated specimens, the addition of Ag led to a considerable improvement in both hardness and compressive strength. The produced alloys with varying amounts of Ag (between 1 and 4wt%) were cold rolled at 400-800r/min and friction coefficients between 0.3 and 0.5. The alloys' ultimate strength rose with an increase in rolling speed for Zn1Cu4Ag, and hardness and compressive strengths rose to 80HV and 470MPa, respectively. It was demonstrated that rolling force rose somewhat with Ag concentration but significantly increased with rolling speed and friction. E. Coli and S. aureus were used to assess the biodegradable alloys' antibacterial properties. For the Zn-1Cu-2Ag alloy, the inclusion of Ag resulted in a considerable (50%) rise in antibacterial activity that exceeded the effects seen in other alloy systems.

Effect of process parameters on the rheological properties of banana (Musa acuminata) fiber and optimization using response surface methodology

The labor-intensive, time-consuming, and uneconomical nature of manually extracting banana (Musa acuminata) fibers from pseudo-stem sheaths has prompted the exploration of automation as a solution. This study focuses on automating the feeding process of banana pseudostem sheaths using a quick return mechanism, which is more effective than other approaches. A comprehensive study was conducted to assess the impact of key process parameters, namely the decorticator (480–540 rpm), roller speed (50–80 rpm), and clearance between rollers (2–4 mm), on the mechanical properties of the extracted banana fiber. The Response Surface Methodology (RSM) was employed for the experimental design and analysis of data, and the mechanical properties under investigation included the tensile strength, Young's modulus, and strain percentage of the banana fiber. The results revealed that the decorticator speed, roller speed, and clearance between rollers are significantly influenced by their mechanical properties. Herein, the optimal process parameter values are identified as follows: a decorticator speed of 510 rpm, roller speed of 65 rpm, and clearance of 3 mm between rollers. The mechanical characterization of the optimized banana fiber exhibited impressive properties, with an ultimate tensile strength of 679.48 MPa, Young's modulus of 25.47 GPa, and strain of 3 %. This study demonstrates that automation coupled with systematic parameter optimization can enhance the mechanical attributes of banana fibers. This research not only addresses the challenges of manual extraction, but also advances the understanding of how process parameters affect banana fiber quality, thereby facilitating the utilization of this natural fiber in various industrial applications.

Sub-rapid solidification microstructure characteristics and control mechanisms of twin-roll cast aluminum alloys: A review

Rapid growth in industrial sectors such as automotive and shipbuilding has highlighted the significance of strip casting technology to produce lightweight alloys, particularly aluminum alloys widely used in both industrial production and daily life. Twin-roll casting (TRC), as an economically and environmentally friendly method for slab/strip production and processing, has attracted significant interest from researchers. However, the development of TRC aluminum alloys faces many challenges due to limited understanding of microstructural characteristics and control mechanisms. To further enhance comprehension of TRC aluminum alloys, this article reviews the influencing parameters, control methods, and existing issues related to TRC sub-rapid solidification (SRS) microstructure. It firstly summarizes TRC equipment types and their solidification characteristics, followed by a detailed analysis on key parameters affecting the evolution of TRC microstructure including rolling speed, roll separation force (RSF), and heat transfer coefficient (HTC). Finally, solutions to TRC defects are summarized and evaluated alongside their underlying mechanisms. This article provides a comprehensive review of the characteristics and control mechanisms of TRC microstructure while offering valuable insights for the future production of high-quality TRC aluminum strips.

Inline Hot Rolling of Al-5%Mg Strip Cast Using an Unequal Diameter Twin-Roll Caster.

One advantage of twin-roll casting for aluminum alloys is that hot rolling can be omitted, thus shortening the process. The effect of inline hot rolling on the anisotropy of the mechanical properties, especially the elongation, of the roll-cast strip has not been investigated. In a high-speed twin-roll caster, inline hot rolling forms the metal shape before the temperature of the cast strip decreases below the temperature needed for hot rolling. In this study, inline hot rolling of Al-5%Mg strips cast using an unequal diameter twin-roll caster was performed to validate the technique and evaluate its ability to reduce surface cracking and improve the elongation anisotropy. A rolling speed of 30 m/min was used, and the effects of temperature and thickness reduction during inline hot rolling on the surface and mechanical properties were investigated. Inline hot rolling was found to effectively reduce the formation of surface cracks and the anisotropy of the mechanical properties.

Design and Experiment of In-Situ Bionic Harvesting Device for Edible Sunflower

In view of the low degree of mechanization and poor quality of harvesting of edible sunflower after drying, an in situ bionic harvesting device was designed, which can achieve low-loss harvesting of edible sunflower without removing the edible sunflower disc. According to the physical characteristics of sunflower stalks in the field, influencing factors of in situ low-loss feeding were obtained, and the structural parameters of the in situ feeding mechanism were determined. Based on bionic technology and static analysis, the influencing factors on the performance of the bionic threshing mechanism were obtained. By analyzing the mechanical characteristics of edible sunflower seed, the operation parameters of the seed collection mechanism were determined. Based on the structural analysis results of the harvesting device, a response surface optimization test was carried out. The test results show that when the average rotation speed of the bionic loosening roller was 113.57 rpm, the average rotation speed of the simulated artificial striking roller was 230.80 rpm, the average forward speed of the harvesting device was 0.58 m/s, the working quality of the harvesting device was the best, the seed loss rate was 2.12%, and the edible sunflower disc threshing rate was 98.96%. A field verification test further confirms that under the optimal working parameters, the relative deviation between test indexes and response surface optimization test results was less than 2%. During the operation process, the movement of key components of the harvesting device was coordinated and stable. The research results can provide new ideas for the mechanized harvesting of the edible sunflower disc after drying.

Study on the influence of rolling process parameters on the microscopic plastic deformation of nickel-based superalloy single crystal at atomic scale

Nickel-based superalloy workpieces strengthened by rolling process are widely used in the aviation field. However, there remains a need for further investigation into the influence of rolling parameters on the micro-plastic deformation of nickel-based superalloys. In this study, we establish micro-rolling and analysis models to investigate the impact of rolling parameters on nickel-based superalloy single crystals. We delve into the micro-effects of rolling depth, rolling speed, roller rotation speed, and roller radius. The micro-analysis model elucidates the influence mechanism of rolling parameters on nickel-based superalloy single crystals. The research methods and findings offer a novel microscopic perspective and approach for studying the strengthening of nickel-based superalloys through rolling. Additionally, they provide a microscopic theoretical foundation for optimizing rolling parameters.

Design and Test of Discrete Element-Based Separation Roller Potato–Soil Separation Device

To address the problems of low bright rates and high rates of potato injuries, a left and right-hand rotation combination of potato–soil separation devices was developed. Its overall structure and working principle were introduced. A Texture Analyzer and pressure sensor were used to measure the force threshold of different varieties of potatoes. A discrete element model of separation rollers and potatoes was established. The collision characteristics of potatoes were analyzed using the device inclination angle, rotational speed, and the center distance of the separation rollers as test factors. A field trial was carried out to optimize the best combination of factors by taking the rate of injured potatoes, bright potatoes, and skin-breaking rate as the test indexes. The force threshold for skin-breaking injury in potatoes was found to be 190–195 N. When the inclination angle of the device was 6°, the rotation speed of the separation roller was 100 r/min, and the distance between the centers of the separation rollers was 79 mm. The rate of injury was 1.25%, the rate of bright potatoes was 99.01%, and the rate of skin-breaking was 1.58%. When the inclination angle of the device was 8°, the rotational speed of the separating roller was 80 r/min, and the center distance of the separating roller was 79 mm, the rate of injured potato was 1.43%, the rate of bright potato was 98.64%, and the rate of broken skin was 1.77%. This paper offers an optimized reference for the effectual removal of sticky soil.

SCIENTIFIC APPROACH TO REDUCING THE ENERGY OF THE PARKING RETARDER POSITION OF A SORTING DEVICE WITH TARGET GRAVITY BRAKING OF CUTS

The main disadvantage of a sorting device with target gravity braking of cuts is the necessity to use a powerful parking retarder position. In order to reduce the energy of this position, it is proposed to install an auxiliary brake position on the descending part of the device to transfer there part of the work on regulating the rolling speed of cuts of a certain mass. For the given operating conditions, the required energy of these positions and the optimal design parameters of the sorting device were determined, and recommendations were developed for braking the cuts at the auxiliary brake position based on the results of simulation modeling of the rolling of the design runners. The structural parameters were optimized using the developed mathematical model, where the height of the sorting device is the optimization criterion. The optimization calculations were performed both for favorable and unfavorable conditions of the runners rolling. The results of the simulation modeling of the rolling of the design runners proved that the maximum braking value at the auxiliary brake position (0.74 m e. h.) for the specified operating conditions is provided when braking the cuts weighing more than 34.8 tons. To simplify the process of braking such cuts at the auxiliary braking position, it is proposed to use low-energy retarders whose rated energy is less than the maximum possible braking value at this position. The reason of it is that when more powerful retarders are used at the auxiliary braking position, not only the degree of braking of each cut should be determined, but also the duration of their braking, which to some extent complicates the process of speed control and may require automation of operation of this position. If low-energy retarders UVSK-11 with the rated energy of 0.6 m e. h. are used at the auxiliary brake position, the required energy of the park brake position is reduced by 0.57 m e. h. At the same time, all cuts weighing more than 30.8 tons should be braked at the auxiliary brake position. Based on the studies, it was concluded that the installation of an auxiliary brake position on the descending part of the sorting device with target gravity braking of cuts would reduce capital investments in construction and mechanization, as well as the costs associated with the operation of this device.

Simulation Analysis and Parameter Optimization of Seed–Flesh Separation Process of Seed Melon Crushing and Seed Extraction Separator Based on DEM

In order to enhance the comprehensive processing quality and production efficiency of seed melons, a seed melon crushing and seed-extraction separator has been developed and designed. Aiming at the issues of high impurity rate and scratch rate of melon seeds in the process of seed–flesh separation, the structure and parameters of the seed–flesh separation device were optimized in this study by simulation analysis and field testing. The simulation model of melon seed, melon flesh, and the seed–flesh separation device based on the discrete element method (DEM) was established, and the simulation parameters were calibrated. Subsequently, the melon seed impurity rate (G1) and the melon seed scratch rate (G2) were used as the evaluation indexes. The single-factor simulation test was carried out on the separation roller speed (A). The spacing between the scraper and the screen (B), the separation roller scraper inclination angle (C), and the influence rules of each factor on the separation effect of the seed–flesh were obtained. Finally, the three-factor and three-level orthogonal test was carried out. Using the method of ANOVA and multi-objective optimization, the optimal working parameters of the device were obtained as A-117.53 r/min, B-5 mm, and C-10°, at which time the optimal evaluation indexes were G1-5.59% and G2-2.85%. The prototype test was carried out with the optimization results. The values of G1 and G2 were measured at 5.71% and 2.91%, respectively, and the relative errors with the simulation values were 2.15% and 2.11%, respectively, which were basically the same between the simulation model and the prototype test. The results indicate that the designed separation roller speed, spacing between the scraper and screen, and separation roller scraper inclination angle can meet the requirements of seed–flesh separation in the seed melon crushing and seed-extraction separator. The results of the DEM study can provide a reference for the optimal design of the seed–flesh separation device.

Optimization of Slugging and Compression Process for Bicalutamide Tablets

The critical nature of pharmaceutical dosage forms necessitates the optimization of manufacturing process variables to achieve the desired product quality. In this study, slugging (Dry granulation) was selected as an appropriate granulation method to mitigate poor flow properties in the final bicalutamide blend. The chosen process variables include slug hardness, mill screen size, and mill speed. A 23-factorial design was employed to investigate these variables. Process parameters were reproducible, with minimal impact on tablet properties, even when roller speeds varied. Response surface models effectively examine the relationship between response variables and quantitative parameters. The input and process variables for the compression process were predetermined based on the desired quality attributes of bicalutamide tablets. Notably, the p-value for the slugging process was not more than 0.05, indicating their insignificance in tablet content uniformity. Product quality attributes affected by the compression process step include content uniformity, disintegration time, and dissolution. The optimal hardness range was found to be 2.0 to 7.0 kp.

A humidity-driven film with fast response and continuous rolling locomotion

The widespread availability and easy accessibility of humidity make it essential to explore simple and low-cost methods to prepare structurally and materially efficient humidity-driven actuators with spontaneous and continuous locomotion to facilitate the application of bionic devices, intelligent sensors, and soft robots. Herein, this paper reports a humidity-driven monolayer film actuator. It is self-assembled from agarose (AG) and graphene oxide (GO) modified with polyvinylpyrrolidone (PVP), referred to as PGO, using a simple casting method. The PGO/AG composite film actuator exhibits an ultra-fast humidity response time (124.58° s−1) and recovery time (18.87° s−1), enabling rapid rolling locomotion driven by water evaporation. Notably, the programmable surface patterning of the PGO/AG composite film actuator with graphite results in a shorter single rolling time (0.43 s) and a faster rolling speed (28.73 mm s−1). Based on these advantages, the PGO/AG film actuator can mimic the opening and closing of flowers, mimosas, and fast-crawling robot driven by periodic water vapor (9.9 body length min−1). This finding provides new insights into the design of multifunctional actuators based on humidity-driven films.

A modified mechanistic approach for predicting ribbon solid fraction at different roller compaction speeds

This research investigates the modeling of the pharmaceutical roller compaction process, focusing on the application of the Johanson model and the impact of varying roll speeds from 1 to 15 RPM on predictive accuracy of ribbon solid fraction. The classical Johanson’s model was integrated with a dwell time parameter leading to an expression of a floating correction factor as a function of roll speed. Through systematic analysis of the effect of different roll speeds on the solid fraction of ribbons composed of microcrystalline cellulose, lactose, and their blends, corrective adjustment to the Johanson model was found to depend on both roll speed and formulation composition. Interestingly, the correction factor demonstrated excellent correlation with the blend’s mechanical properties, namely yield stress (Py) and elastic modulus (E0), representative of the deformability of the powder. Validated by a multicomponent drug formulation with ±0.4–1.3 % differences, the findings underscore the utility of this modified mechanistic approach for precise prediction of ribbon solid fraction when Py or E0 is known for a given blend. Hence, this work advances the field by offering early insights for more accurate and controllable roller compaction operations during late-stage pharmaceutical manufacturing.

Improving the Mechanical Properties of Hot Rolled Low-Carbon Copper-Containing Steel by Adjusting Quenching Roll Speed.

This paper presents a comprehensive study of the impact of quenching roll speed on enhancing the low-temperature toughness of a low-carbon copper-containing steel. The microstructure characteristics, such as the prior austenite grains, and the distribution and volume fraction of precipitates, are observed using optical microscopy, scanning electron microscopy, transmission electron microscopy, and small-angle scattering X-ray. The results show that a decrease in the quenching roller speed (2 m/min) contributes to the achievement of more excellent low-temperature toughness (the average value is 232 J), although the prior austenite grains exhibit a relatively larger size in this case. The tempering treatment results in the precipitation of a large amount of 9R-type Cu-rich particles, regardless of the quenching roller speed. Reducing the quenching roller speed contributes to the increase in the volume fraction of Cu-rich particles, which is considered to be the main factor contributing to the achievement of excellent low-temperature toughness.

The tail segments are required by the performance but not the accomplishment of various modes of Drosophila larval locomotion

The tail plays important roles in locomotion control in many animals. But in animals with multiple body segments, the roles of the hind body segments and corresponding innervating neurons in locomotion control are not clear. Here, using the Drosophila larva as the model animal, we investigated the roles of the posterior terminal segments in various modes of locomotion and found that they participate in all of them. In forward crawling, paralysis of the larval tail by blocking the Abdb-Gal4 labeled neurons in the posterior segments of VNC led to a slower locomotion speed but did not prevent the initiation of forward peristalsis. In backward crawling, larvae with the Abdb-Gal4 neurons inhibited were unable to generate effective displacement although waves of backward peristalsis could be initiated and persist. In head swing where the movement of the tail is not obvious, disabling the larval tail by blocking Abdb-Gal4 neurons led to increased bending amplitude upon touching the head. In the case of larval lateral rolling, larval tail paralysis by inhibition of Abdb-Gal4 neurons did not prevent the accomplishment of rolling, but resulted in slower rolling speed. Our work reveals that the contribution of Drosophila larval posterior VNC segments and corresponding body segments in the tail to locomotion is comprehensive but could be compensated at least partially by other body segments. We suggest that the decentralization in locomotion control with respect to animal body parts helps to maintain the robustness of locomotion in multi-segment animals.

Modified Roller Compaction Model to Account for Roll Speed Effect on Powder Compaction in Dry Granulation Process

This study introduces a modification to the roller compaction model proposed by Sousa et al.1 to account for the effect of roll speed on powder compaction in the dry granulation process. The proposed model enhances the prediction accuracy, particularly at higher roll speeds, which are often overlooked in existing models. The modified model is validated using literature data, demonstrating improved performance compared to the original model. Additionally, the model is applied to a pharmaceutical formulation, showing its applicability in an industrial context. The integration of the model into gPROMS allows for global sensitivity analysis and design space exploration, providing valuable insights for process optimization and scale-up. The study contributes to the understanding of roller compaction dynamics and offers a practical tool for decision-making in pharmaceutical manufacturing.