Squeeze Rolls Research Articles

Redesign of the sizing process optimization to produce warp yarn with strong weaving ability

The research focuses on optimization of the sizing process parameters for cotton warp yarn material. The sizing process is a crucial step where warp yarn is coated with a starch solution before weaving. The aim is to produce warp yarn with strong weaving ability, thereby facilitating the entire process. To achieve this, several factors are considered, namely the steam bar, and squeeze roll pressure, including machine speed. The techniques used to address this issue include Taguchi in collaboration with Grey Relational Analysis (GRA) to effectively address multi-responses. In this analysis, the larger the better characteristic was applied to S/N Ratio, indicating that the higher the GRG value, the closer it is to the desired optimum condition. Based on the calculations from S/N Ratio response table for the GRG, it can be determined that factor steam bar pressure was selected at 4 Bar, with an average S/N Ratio value of -2.935. factor squeeze roll should be set to level 10 Km/m3, as it yields an average S/N Ratio value of -2.912. Factors squeeze roll) and C (Machine Speed) were selected at levels 2 (10 Km/m3) and 1 (45 M/Min) with average values of -2.912, and -4.771, respectively.

The Use of the Linear Energy Calculation Model in High-Frequency Induction (HFI) Tube Welding Technology to Obtain Optimal Microstructure and Weld Geometry

The article presents a calculation model of the linear energy of welding P235GH steel tubes with high-frequency currents in order to obtain an optimal microstructure and geometry of the weld of high internal purity. The model was developed based on real data for the standard linear energy used in the steelworks Huta Łabędy and presented as the power factor P/V and P/(V·t), where P is the power [kW], V the production speed [m/min] and t the wall thickness. The model can be used for two ranges of pipe diameters: 114.3–168.3 mm and 219.1–323.9 mm. The data from the model were implemented into the High Frequency Induction (HFI) control panel of Huta Łabędy in order to produce test tubes which were subsequently tested with ultrasounds to verify the quality of the internal weld. In addition, samples were taken for metallographic analysis, which was supposed to check whether the applied linear energy calculation model allows the obtainment of the optimal weld geometry and the optimal angle of the metal flow line allowing for swelling and the extrusion of melted impurities from the inside of the joint by the squeeze rolls. The metallographic analysis also determined the nature of the occurrence of ferrite inside of the center diffusion bond and the zonal microstructure of the joint, the control of which is based on the correlation of the parameters of the mechanical process of forming the tube with the linear energy of welding. Carrying out the technological and technical process based on the applied HFI linear energy calculation model allowed us to obtain a weld of high purity and metallurgical consistency. This model can be used in the future on an industrial scale for the production of pipes using the HFI method.

Numerical Simulation of Tube Manufacturing Consisting of Roll Forming and High-Frequency Induction Welding.

This paper presents a fully coupled three-dimensional finite element model for the simulation of a tube manufacturing process consisting of roll forming and high-frequency induction welding. The multiphysics model is based on the dual mesh method. Thus, the electromagnetic field, the temperature field, the elasto-plastic deformation of the weld bead, and the phase transformations within the material can be simulated for a moving tube without remeshing. A comparison with measurements shows that the geometry of the welded tube and the weld bead, the force on the squeeze rolls, the temperature along the band edges, and the hardness distribution within the heat-affected zone can be simulated realistically.

Research on the optimization of welding parameters in high-frequency induction welding pipeline

In this paper, numerical simulation and finite element analysis were applied to optimize the important parameters including V-type joint and current frequency for high-frequency induction welding. The coupling of the 3D harmonic electromagnetic field and 3D transient temperature field was analyzed by establishing the physical file of the electromagnetic field and temperature field in high-frequency induction welding. The influence of important welding parameters on the temperature field distribution in the welding area was obtained by using a single control variable method. In the temperature field, the size of the V-type joint determines the heating efficiency, and the current frequency affects the heat produced by the eddy current. The numerical simulation results were verified by the analysis of the actual production experimental results and a good process parameter group was summarized. The shape of the slit between the different V-type joint parameters and the centerline of the squeeze roll showed that the relationship of the welding image and the welding quality and provided a solution for real-time online monitoring of welding quality.

Development of Methods to Improve the Mechanical Performance of Coated Grid-Like Non-Crimp Fabrics for Construction Applications

This paper presents investigations aiming to improve the impregnation of a coating agent and thus increase the mechanical performance of geogrids, especially grid-like non-crimp fabrics (NCF) consisting of carbon fiber heavy tows (CFHT). The squeezing process is industry standard, but the relationship between the machine setting parameters (squeezing pressure and hardness of squeeze roll surface) and the impact on the tensile strength of grid-like NCF is still unexplored. The setting parameters evaluated lead to an increase in tensile strength of up to 10% compared to grid-like NCF coated without the squeezing process. Additionally the first insights into the coating process supported by ultrasonic vibrations based on CFHT single yarns are provided. It is shown that the tensile strength of treated CFHT can be increased by up to 12%, in comparison to CFHT coated without ultrasonic vibrations.

Comparison analysis and parameter study for roll separation force to avoid bearing failure in tube mills

This paper reports the reaction force acting on the various rollers of roll forming tube mills. The roll separation force is the major criteria for designing of tube mill structures as well as bearing selection for tube mills. Cold condition tube pass in squeeze roll produces high roll separation force causing Bearing failure in tube mills. The frequent failure of bearings due to over load in squeeze roll is important issue in tube manufacturing industries in this current era. we studied the roll separation force by FEM simulation with three different materials with different strength includes High Strength Low Alloy Steel (yield strength of 750MPa and ultimate strength of 900MPa), St 52 (DIN 17135 Standard, yield strength of 400MPa and Ultimate strength of 500 MPa) and SAE 1010 (yield strength of 350MPa and ultimate strength of 550MPa). The piecewise linear plasticity material is selected in LS-Dyna material database for this simulation. The comparison study states that the increase in strength increases roll separation force. Increase in load is observed with decrease in D/T (diameter to thickness ratio).

Effect of HF Welding Process Parameters and Post Heat Treatment in the Development of Micro Alloyed HSLA Steel Tubes for Torsional Applications

The aim of the present study is to investigate the effect of High frequency (HF) Electric resistance welding process parameters and post heat treatment on the torsional fatigue life of micro alloyed HSLA steel tubes. Micro alloyed grades exhibit higher strength and formability owing to the presence of fine recrystallized ferritic grains due to thermo mechanical treatment and presence of alloying elements like Vanadium, Niobium and Titanium. Welded tubular components made of micro alloyed HSLA steel grades are highly emerging and manufacturing them remains quite challenging. Weld bond width, HAZ width and bond angle are the significant factors that directly influences the Weld quality and strength. The effect of key welding parameters like Heat input, welding temperature, squeeze roll pressure, Vee-angle, Vee-length and Impeder diameter on the above mentioned significant factors was analysed. Narrow bond, Minimum HAZ width with pronounced Hour glass pattern and optimum bond angle resulted in superior bond strength and formability of HSLA tubes. Microstructural characterization of the samples was carried out using Light optical microscopy and Scanning electron microscopy. Residual stress was determined using X-ray diffract meter and tube slitting method. Higher tensile residual stress of magnitude 200 MPa was observed in the weld region. Since such high magnitude of tensile residual stress is detrimental to torsional fatigue life, stress relieving of the tubes was carried out at different subcritical temperatures 650°C and 700°C with soaking time of 45 minutes. Without significant drop in the tensile properties, compressive residual stress of magnitude 129 MPa was observed at a particular stress relieving cycle. As an effect of stress relieving heat treatment below Ac1 temperature, there is a significant improvement in the Torsional fatigue life of the HSLA steel. Thus, High Frequency welded micro alloyed HSLA steel tubes with enhanced torsional fatigue performance were successfully developed.

TG comparison between the efficiency of deposited ammonium bromide and ammonium chloride on the flame-retardancy imparted to cotton fabric

Abstract This study investigates the effect of ammonium bromide and/or ammonium chloride as nondurable finishes on the flammability of 100% cotton fabric, (woven construction, weighing 144 g m−2). The laundered bone-dried, weighed fabrics were impregnated with suitable concentrations of aqueous ammonium bromide and/or ammonium chloride solutions by means of squeeze rolls and dried at 110°C for 30 min. Afterwards they were cooled in a desiccator, re-weighed with an analytical precision and kept under ordinary conditions before the fulfillment of the vertical flame test. The optimum add-on values to impart flame retardancy expressed in g anhydrous ammonium bromide and ammonium chloride per 100 g fabrics were individually obtained to be about 3.5–3.89 and 17.31–17.99%, respectively. Thermogravimetric analysis (TG/DTG) of pure cotton and the salts treated fabrics were fulfilled and their curves were compared and commented. The results obtained comply with free radical theory, and also proved the superiority ...

TG of a cotton fabric impregnated by sodium borate decahydrate (Na2B4O7·10H2O) as a flame-retardant

The effect of sodium borate decahydrate as a nondurable treatment on the flammability of 100% cotton fabric (woven plain 150 g m−2) has been investigated in this paper. The laundered bone-dried massed samples were impregnated with suitable concentrations of sodium borate decahydrate. Each bunches of fabrics were dipped into individual aqueous solutions of the salt, followed by means of squeeze rolls and drying at 110°C. By using a ‘vertical flame spread test’ the optimum add-on values to impart flame-retardancy onto cotton fabric was determined to be as 4.24 g salt per 100 g fabric. The objective of this study is thermogravimetry (TG) investigation of pure cotton, treated one with the salt at its optimum efficiency. So that outcomes could be compared and commented, finally the results obtained are in favor of ‘Chemical action theory’, ‘Condensed phase retardation’, ‘Dust or wall effect theory’ and also ‘Gas dilution theory’.

Thermogravimetric Analysis of a Cellulosic Fabric Incorporated by Lithium Hydroxide as a Flame Retardant

The effect of lithium hydroxide on the flammability of cotton fabric (Woven, 180 g/m2) is studied in this investigation. The aforementioned hydroxide was applied using the suitable concentrations of its individual solutions onto bone dried and weighed cotton fabrics. They were impregnated by means of squeeze rolls. They were then dried in an oven at 110°C for 30 min, cooled in a desiccator, weighed with analytical precision and kept under ordinary conditions before the fulfillment of the flame test. The optimum add-on values to impart flame retardancy were about 2.38–2.76 g anhydrous lithium hydroxide per 100 g cotton fabric. The results obtained agree with thermal theory. However, after the ignited specimens ceased to flame, the presence of glow was not observed. Hence the condensed phase retardation can be justified.

XRD characterization of the ashes from a burned cellulosic fabric impregnated with magnesium bromide hexahydrate as flame-retardant

The effect of magnesium bromide hexahydrate [MgBr2·6H2O] as a nondurable finish on the flammability of 100% cotton fabric, (woven construction, massing 150 g m−2) has been investigated. The laundered bone-dried, massed fabrics were impregnated with various concentrations of the aqueous above-mentioned salt solutions by means of squeeze rolls and drying in an oven at 110°C for 30 min. The specimens were then cooled in a desiccator, re-massed with an analytical balance and kept under standard conditions before the fulfillment of the vertical flame spread test.

Thermogravimetric Analysis of a Cellulosic Fabric Incorporated by Synthetic Ammonium Magnesium Phosphate as a Flame-Retardant

We have investigated the effect of synthetic struvite (MgNH4PO4·6H2o) on the flammability of a cellulosic fabric. It was synthesized by means of the multiple-bath method and deposited onto a cotton fabric. Its uniformity was ensured by means of squeeze rolls, obtaining the optimum effective add-on value of ammonium magnesium phosphate to impart flame retardancy to cotton fabric in the range of around 12 g anhydrous salt per 100 g fabric. A thermogravimetric analysis of pure cotton, treated cotton, and the salt was accomplished, and their thermograms were compared and commented upon. The results obtained fortified the chemical theory expressing the promotion of the formation of solid char rather than the formation of volatile pyrolysis products, during the fulfillment of thermal decomposition of the cellulosic substrate.

Verification Concerning the Relative Superiority of a Cellulosic Fabric with Regard to Polyester in Terms of Flammability

In order to prove the superiority of cotton fabric to polyester with regard to flammability, we have studied the effect of Graham's salt as a moderate and nondurable finish on the flammability of pure polyester and cotton fabric. The laundered bone-dried, weighed fabrics were impregnated with suitable concentration of aqueous Graham's salt solutions by means of squeeze rolls and drying at 110°C for 30 min. They were then cooled in a desiccator, reweighed with analytic precision, and kept under ordinary conditions before the accomplishment of the vertical flame test. The optimum add-on value to impart flame retardancy was about 43.65% for polyester fabric and 36.78% for cotton fabric. The results obtained comply with the Coating Theory. Moreover, the superiority of cotton fabric to polyester fabric in terms of combustibility has been deduced.

Combustion pathway of cotton fabrics treated by ammonium sulfate as a flame-retardant studied by TG

The effect of ammonium sulfate (NH4)2SO4 on the flammability of 100% cotton woven fabric (plain 144 g m−2, the number of yarns 21 per 10 mm) has been of interest in this study. The laundered bone-dried, massed fabrics were impregnated with suitable concentration of aqueous ammonium sulfate solutions by means of squeeze rolls, drying and conditioning. Afterwards the specimen’s resistance to burning has been determined. The optimum add-on value of ammonium sulfate to impart flame-retardancy to cotton fabric was in a range about 10.55–13.62 g anhydrous salt per 100 g fabric.

Ammonium Chloride as a Flame Retardant in a Polyester Fabric and its Detection

The effect of ammonium chloride as a nondurable finish on the flammability of 100% polyester fabric has been investigated. The laundered, bone-dried, weighed fabrics were impregnated with a suitable concentration of aqueous ammonium chloride solution by means of squeeze rolls and drying at 110°C for 30 min. They were then cooled in a desiccator, re-weighed in an analytical balance and kept under ordinary conditions before the fulfillment of the vertical flame spread test. The optimum add-ons to impart flame retardancy were about 20.21–21.87 g anhydrous ammonium chloride per 100 g fabric. These results comply with the Free Radical Theory. Finally, the Mohr analytical test method was used to detect the salt content in finished fabrics.

Spectrophotometric Detection of Inhomogeneous Distribution of Ammonium Copper (II) Phosphate Flame-Retardant in a Cellulosic Fabric

Ammonium copper (II) phosphate [CuNH4PO4] was synthesized by means of a multiple bath method and deposited onto a laundered and dried weighed cotton fabric (woven plain construction, 180 g/m2). This was followed by means of squeeze rolls and drying at 110°C for 30 min. The specimens were then cooled in a desiccator, re-weighed with analytical precision and kept nightlong under ordinary conditions, before the performance of the vertical flame test. The optimum addition of CuNH4PO4 to impart flame-retardancy to cotton fabric was about 13.96%. The outcomes of the vertical flame test are in compliance with Dust or Wall Effect Theory. The estimation of inhomogeneity's distribution in different parts of a selected specimen was accomplished via spectrophotometric analysis and the results express the heterogeneous distribution of the salt in various sectors of the fabric.

Thermogravimetry of deposited caustic soda used as a flame-retardant for cotton fabric

We have investigated the effect of caustic soda as a nondurable finish on the flammability of 100% cotton fabric (plain 180 g m−2). On the contrary to the mercerization, during the impregnation process, no tension was applied. In order to attain the alkali cellulose onto the fabric, the subsequent neutralization was not followed. Each bunches of fabrics were dipped into individual aqueous solutions of sodium hydroxide, followed by means of squeeze rolls and drying at 110°C. After conditioning nightlong, by using our ‘vertical flame test’ the optimum add-on values to impart flame-retardancy into cotton fabric was determined as 1.3 g sodium hydroxide per 100 g fabric. Thermogravimetry and derivative thermogravimetry (TG/DTG) of pure cotton, treated cotton with sodium hydroxide at its optimum efficiency to impart flame-retardancy into the fabric was fulfilled and the obtained curves were compared and commented. The effectiveness of this hydroxide is attributed to the heat dissipation by the remaining material in the consumed ash. The results obtained are in favour of ‘dust or wall effect theory’ and also gas dilution theory.

Thermal decomposition pathway of a cellulosic fabric impregnated by magnesium chloride hexahydrate as a flame-retardant

We have investigated the effect of magnesium chloride hexahydrate [MgCl2·H2O] as a nondurable finish on the flammability of 100% woven cotton fabric, (plain construction, with a density of 144 g m−2, the number of yarns 21/10 mm). The laundered bone-dried, massed fabrics were impregnated with suitable concentrations of aqueous solution of the above-mentioned salt, by means of squeeze rolls. They were then dried horizontally in an oven at 110°C for 30 min. The optimum add-on value after the fulfillment of vertical flame spread test to donate flame-retardancy onto cotton fabric was obtained to be in the range of 6.73–8.30 g of the salt per 100 g fabric. Thermogravimetry (TG) of pure cotton, treated cotton and the salt was accomplished, and their TG curves were compared and commented. The results obtained are in favor of the ‘gas dilution theory’, chemical action theory and also in compliance with the ‘free radical theory’. The formation of sal ammoniac was proven by sprinkling concentrated ammonia upon the inflamed treated specimen.

Thermogravimetric Analysis of a Cellulosic Fabric Incorporated with Ammonium Iron (II)-Sulfate Hexahydrate as a Flame-retardant

The effect of ammonium iron (II)-sulfate hexahydrate [(NH4)2Fe (SO4)2.6H2O] as a nondurable finish on the flammability of 100% cotton fabric, (woven construction, weighing 144 g/m2) has been investigated. The laundered bone-dried, weighed fabrics are impregnated with suitable concentrations of the above-mentioned salt solution by means of squeeze rolls and drying at 110°C for 30 min. They are then cooled in a desiccator, re-weighed with an analytical balance, and kept under ordinary conditions before the fulfilment of the vertical flame test. The optimum add-on values to impart flame-retardancy expressed in g anhydrous ammonium iron (II)-sulfate hexahydrate per 100 g fabric are about 23.62—25.82%. Thermogravimetric analysis (TGA/DTG) of pure cotton, treated cotton, and the salt is fulfilled and their thermograms are compared and commented. The results are in compliance with `Gas theory' and `Chemical theory'.

Thermogravimetric Studies of Deposited Potash Impregnated for Flame‐Retardancy into a Cotton Fabric

AbstractThe effect of potash as a nondurable finish on the flammability of 100% cotton fabric (plain 180 g/m2) was investigated. The bone‐dried weighed fabrics were dipped into suitable concentrations of potash, with a volume of 100 mL at 20–2 °C. The impregnation was followed by means of squeeze rolls and drying at 110 °C. The samples were then reweighed with analytical precision. After conditioning overnight by using our "vertical flame tester" the optimum add‐on values to impart flame‐retardancy to cotton fabric was determined and expressed by 0.80 g of potash per 100 g fabric to be an efficient addition. Thermogravimetric analysis of pure cotton, treated cotton with potash at its optimum efficiency for donation of flame‐retardancy into cotton fabric was fulfilled and the thermograms were compared and commented. The effectiveness of this hydroxide was attributed to the heat dissipation by the remaining consumed material during the combustion. The results obtained are in favor of "Dust or Wall Effect Theory".